Pacific Industrial Co., Ltd. Business Report FY ended Mar. 2013
Business Highlights
Financial Overview |
(in millions of JPY) |
FY ended Mar. 31, 2013 | FY ended Mar. 31, 2012 | Rate of Change (%) |
Factors | |
Overall | ||||
Sales | 83,700 | 79,579 | 5.2 | - |
Operating income | 4,340 | 3,699 | 17.3 | - |
Ordinary income | 5,372 | 4,147 | 29.5 | - |
Net income | 2,807 | 3,297 | (14.9) | - |
Stamping/resin product business | ||||
Sales | 59,614 | 56,841 | 4.9 | -Sales increased due to the recovery in vehicle production at OEMs in Japan and the U.S.A., the Company’s major markets; even though sales were negatively impacted by the boycott on buying Japanese-brand products in China. |
Operating income | 1,449 | 1,669 | (13.2) | -Profit was lower year-on-year due to the rising costs of materials and initial start-up expenses incurred with launching business operations in China. This was in spite of higher sales, effective cost-cutting initiatives, and lower depreciation expenses for the year. |
Valve product business | ||||
Sales | 23,747 | 22,361 | 6.2 | -Sales were higher year-on-year as a result of the Company’s selling more TPMSs (Tire Pressure Monitoring Systems) in the U.S.A., a major market; more product sales to Japanese OEMs, who also experienced a recovery in sales; and greater sales of tire-valve cores and other valves. |
Operating income | 2,928 | 2,040 | 43.5 | -Greater sales volumes and actions taken to respond to the high valuation of the yen contributed to improved sales year-on-year. |
Recent Development in Japan
Strengthening Production Operations for Stamped Parts-The Company is going to enhance its production structure for stamping parts, positioning the Chubu region, the Kyushu region and the Tohoku region as its three major production bases. The Company will introduce its new production method, which is already employed at its Higashi Ogaki Plant in Chubu, also to its facilities in Kyushu and Tohoku. The advanced manufacturing technology enables increased sharing of welding equipment, which contributes to reducing the amount of investment needed to deal with model changes. Adoption of the production system has also allowed the Company to produce multiple products on a single production line. Leveraging the new manufacturing system based on the three-pole production structure in Japan, the Company aims to establish an optimum supply system that can flexibly cope with demand fluctuations. (From an article in the Nikkan Jidosha Shimbun on Nov. 22, 2012)
Recent Development Outside Japan
<USA>Launch of Tire-pressure Monitoring Systems
-The Company is going to expand its capacity to produce tire pressure monitoring systems (TPMSs) in the U.S. to 6 million units a year by FY2014. The Company's domestic plant in Gifu Prefecture has been producing TPMSs for both Japan and the U.S. markets, having a yearly production capacity of 12 million units. Pacific Manufacturing Ohio Inc., the company's U.S. subsidiary, started making TPMSs in the summer, as part of the Company's initiatives to ensure stable supply even at the time of disasters like the Great East Japan Earthquake in March 2011 that caused serious supply chain disruptions. The Company is planning to invest 1 billion yen to establish an optimum production structure at the U.S. plant, with a goal to raise its yearly production capacity in steps to 6 million units by FY2014. The expansion is expected to heighten the company's global TPMS production capacity to 18 million units by FY2014, up 50 percent from the current level. Pacific Industrial is looking to supply its U.S.-made TPMS not only to its North American customers, but also to its European customers, starting by as early as March 2013 as a measure to increase its supply efficiency and cost competitiveness. This expansion is intended to boost sales at the Company's TPMS business to 10 billion yen by FY2015. (From an article in the Nikkan Jidosha Shimbun on Oct. 29, 2012)
Medium-term management plan OCEAN-15
OCEAN-15 numerical targets | FY2015 (Planned) |
|
Sales | 95 billion yens | |
Ordinary income | In the 6% range | |
Percentage of revenue generated overseas | Over 40% | |
Total asset turnover | 1.05 |
Outlook for FY ending Mar. 31, 2014 |
(in millions of JPY) |
FY ending Mar. 31, 2014 (Forecast) |
FY ended Mar. 31, 2013 (Actual Results) |
Rate of Change (%) |
|
Sales | 85,000 | 83,700 | 1.6 |
Operating income | 5,000 | 4,340 | 15.2 |
Ordinary income | 5,500 | 5,372 | 2.4 |
Net income | 3,600 | 2,807 | 28.3 |
Awards
-The Company announced that it has received the "Parts Standardization Award" and "Excellent Quality Control Award" from Toyota. (From a press release on March 27, 2013)R&D
R&D Expenses |
(in millions of JPY) |
FY ended Mar. 31, 2013 | FY ended Mar. 31, 2012 | FY ended Mar. 31, 2011 | |
Overall | 647 | 603 | 735 |
-Stamping/resin products business | 133 | 122 | 114 |
-Valve products business | 447 | 344 | 84 |
-In Common | 58 | 133 | 525 |
R&D Structure
-The R&D activities of the Company are being conducted by the R&D technical functions and the production-technology functions at each division, with the R&D Technical Planning Department in charge of activities designed to create products for the future. The R&D functions collaborate with each other in developing new materials and production methods so as to develop new products and strengthen the Company's competitive advantages. -The Company's subsidiary, PI Systems, conducts R&D activities on software.
-The Company is working to improve its expertise so as to achieve deeper, more advanced, and newer technology, as well as speed up its development results.
R&D Activities
Business segment |
Departments |
Major activities |
Stamping/resin products business | -Technical Planning Department -R&D Department No. 1, Production Technology Department |
-The Company researched and developed new stamping methods, including cold stamping technology for ultra high-tensile steel. -The Company conducted R&D activities on forming technology in order to achieve producing plastic products that are lighter, provide better sound proofing, and have better thermal insulation properties. -In developing new production methods, the Company is working to reduce VOCs (based on paint-less technology) and CO2, working to develop technology on pre-colored materials. |
Valve products business | -R&D Department No. 2, Production Technology Department, and TPMS Department | -Tire-valve products: the Company developed a metal-look, plastic valve cap based on the idea of combining dies and materials. -Valves for air-conditioners: The Company is developing valve cores for energy-saving air-conditioners by changing the rubber material used for them. -TPMS: As successors to its current TPMSs, the Company developed TPMSs for small, light-weight compact cars, with the aim of increasing their content rate. These new TPMSs demonstrate excellence in terms of their easy-to-install feature, enabling them to be installed easily on wheels. -High-precision stamped parts: The Company is working on ways to expand uses for parts based on commercializing actuators for electric brakes. |
Common | -Technical Planning Department | -R&D activities on compound materials -R&D activities on metal-plasticity processing -The Company is developing products designed for its TPMSs. -The Company is working to develop environmentally friendly products that require less materials and reduce environmental impact. |
Product Development
Double-chamber oil pan-Jointly developed a double-tank oil pan with Toyota. The Company was presented the Award for Best Automotive Part in the 2012 "Product-Creation Parts Competition" sponsored by the Monozukuri Nippon Conference and the Nikkan Kogyou Shinbun (Daily Industrial Newspaper)
Mass-damper
-The Company achieved making a mass-market mass-damper by using sheet-metal-laminating technology, winning the Parts Standardization Award from Toyota in 2013.
Engine Cover
-The world's first technology making it possible to lighten the weight of materials through chemical foam molding and paint-less processes, enabled the Company to create the engine cover being mounted on the new Toyota "Crown". It won the Project Certificate of Recognition.
Investment Activities
Capital Expenditure |
(in millions of JPY) |
FY ended Mar. 31, 2013 | FY ended Mar. 31, 2012 | FY ended Mar. 31, 2011 | |
Stamping/resin products | 4,209 | 4,688 | 3,074 |
-In Japan | 2,012 | 3,322 | 2,687 |
-Outside Japan | 2,197 | 1,366 | 387 |
Valve products | 3,610 | 2,139 | 1,936 |
-In Japan | 987 | - | - |
-Outside Japan | 2,623 | - | - |
Others | 30 | - | - |
Elimination | (29) | - | - |
Total | 7,820 | 6,855 | 5,065 |
<Stamping/resin products>
-In Japan, the Company made capital investment mainly for dies, enabling it to produce new products for new-model vehicles.
-Outside Japan, the Company invested to prepare for production of new products at its stamping facilities in China and North America.
<Valves>
-In Japan, the Company mainly invested to upgrade assembly lines for TPMSs and increase production of valves.
-Outside Japan, the Company invested to increase production of compressors in Korea. It also invested in production facilities for TPMSs in the U.S.A.
Investment Outside Japan
<Thailand>-The Company will construct a new plant in Thailand by 2013 with the aim of localizing production of resin products like wheel caps as well as expanding production capacity of tire valves. The new plant will be built as a second facility of Pacific Industrial (Thailand), a subsidiary in Thailand, at a site adjacent to the No.1 plant in the suburbs of Bangkok. About 700 million yen (approx. USD 8.7 million) will be invested. The new facility with a comprehensive production line of tubeless tire valves will produce resin parts like wheel caps and center ornaments. The plant will commence production of components in December 2013 for delivery to automakers like Honda, Suzuki and Toyota. (From an article in the Nikkan Jidosha Shimbun on Nov. 2, 2012)
<China>
-The Company decided to postpone a project to construct a new plant in Hunan Province, China. Given a decline in production and sales at Japanese-affiliated automakers in China in the wake of protest rallies against Japan and Japanese goods, the Company determined to put on hold the construction project for the time being. Pacific Industrial was awarded contracts by GAC Mitsubishi Motors for automobile body and stamping parts in the compact SUV "ASX" also known as "RVR" in Japan. In fall last year, the company established a new subsidiary Changsha Pacific Hanya Auto Parts Co., Ltd. and made a contract to lease a rental plant in Hunan Province for starting a welding process. The plant currently assembles stamping products by using components supplied from Pacific Industrial's subsidiary in Tianjin. In expectation of continued orders from GAC Mitsubishi for next-generation models, Pacific Industrial planned to set up its own production facility two kilometers from the rental plant and conduct a comprehensive production in that area. The Company intended to make an investment of 2 to 3 billion yen (approx. $25-37.5 million) and to begin the plant construction by March 2014. (From an article in the Nikkan Jidosha Shimbun on Oct. 31, 2012)
Planned Capital Investments
|
(As of Mar. 31, 2013) |
Facility (Location) |
Business segment | Purpose | Planned total investment (in million JPY) |
Start | Planned completion | Production capacity growth after completion |
The Company Nishi Ogaki Plant (Gifu Pref., Japan) |
Stamped and resin | New products, etc. | 3,157 | Jan. 2012 | Sep. 2014 | - |
The Company Higashi Ogaki Plant (Gifu Pref., Japan) |
Stamped and resin | New products, etc. | 2,289 | Mar. 2012 | Mar. 2015 | - |
The Company Yoro Plant (Gifu Pref., Japan) |
Stamped and resin | Production expansion, etc. | 212 | Jan. 2008 | Apr. 2014 | - |
The Company Tohoku Plant (Miyagi Pref., Japan) |
Stamped and resin | Production expansion, etc. | 2,120 | Mar. 2013 | Dec. 2014 | Expand product-plant building; install stamping facilities |
The Company Kyushu Plant (Fukuoka Pref., Japan) |
Stamped and resin | New products | 900 | Aug. 2012 | Jul. 2014 | - |
The Company Kita Ogaki Plant (Gifu Pref., Japan) |
Valve | New products, etc. | 996 | Nov. 2011 | Jan. 2016 | - |
The Company Mino Plant (Gifu Pref., Japan) |
Valve | Production expansion, etc. | 388 | Oct. 2012 | Oct. 2014 | - |
The Company Headquarters (Gifu Pref., Japan) |
Common | R&D, etc. | 322 | Dec. 2012 | Sep. 2014 | - |
Pacific Manufacturing Ohio, Inc. (Ohio, USA) |
Stamped and resin, Valve |
New products, etc. | 1,362 | Apr. 2013 | Mar. 2014 | New production facilities for TPMSs |
Pacific Valve (Taiwan) Co., Ltd. (Taichung, Taiwan) |
Stamped and resin, Valve |
Maintenance and retooling, etc. | 31 | Apr. 2013 | Mar. 2014 | - |
Pacific Valve Industrial Co., Ltd. (Yangsan, Korea) |
Valve | Maintenance and retooling, etc. | 71 | Jan. 2013 | Dec. 2013 | - |
Pacific Air Controles Co., Ltd. (Asan, Korea) |
Valve | Production expansion, etc. | 1,131 | Jan. 2013 | Dec. 2013 | Increase production facilities for compressors |
Pacific Industries (Thailand) Co., Ltd. (Chachoengsao, Thailand) |
Stamped and resin | Maintenance and retooling, etc. | 512 | Apr. 2013 | Mar. 2014 | Expand production-plant buildings; add production facilities producing plastic products and valves |
Valve | New products, etc. | 495 | Apr. 2013 | Mar. 2014 | ||
Tianjin Pacific Auto Parts Co., Ltd. (Tianjin, China) |
Stamped and resin | New products, etc. | 1,966 | Jan. 2013 | Dec. 2013 | Expand stamping processes |
Changsha Pacific Hanya Auto Parts Co., Ltd. (Changsha, China) |
Stamped and resin | New products, etc. | 2,689 | Jan. 2013 | Dec. 2013 | Construct plant building; install new stamping machines |