Shiroki Corporation - Business Report FY2006
Business Highlights
(in million JPY) | FY2006 | FY2005 | Rate of Change | Factors |
Sales | 133,509 | 123,003 | 8.5% | Besides the increase in domestic production volume due to brisk export sales by Japanese automakers, the increase in sales was the result of sales activities based on winning new orders worldwide and developing new products. |
Operating income | 3,182 | 2,019 | 57.6% | Profitability improved thanks to rationalization initiatives. |
Ordinary
income |
3,189 | 2,984 | 6.9% | |
Net income |
1,612 | 1,221 | 32.0% |
Recent Developments by Region
Japan
- Unconsolidated sales increased by 5,878 million yen or 6.2% year-on-year,
to 100,928 million yen, hitting a record high and exceeding 100
billion on an unconsolidated basis for the first time. This was
due to increased sales in connection with higher export volume by
its customers; increased orders for new products such as seats with
slow-movement mechanisms, new types of window regulators; production
increases of vehicle models with high content rates of the Company's
products; as well as the benefits gained from the launch of the
remodeled Corolla, one of Toyota's best-selling mass-market models.
.
- By customer, sales to the Toyota Group increased favorably by
9.4% year-on-year or 5,397 million yen, to 62,866 million yen total.
As a result sales in Japan reached 100,934 million yen (up by 6.4%)
while operating profit was at 2,376 million yen (up 19.1% year-on-year).
- Kyushu Shiroki Co., Ltd., located in Kita Kyushu, Japan, has began
preparing to produce window regulators, the Company's major product.
The Company is planning to commence full commercial operations at
a second plant in May 2007. The Company responded to increased production
volume of automakers in Kyushu and to new orders it won, while at
the same time improving the production efficiency of its two plants.
Shiroki Shoji Co., Ltd., located in Anjo City, Japan, was spun
off in July 2006 to enhance the efficiency of group operations.
In its place the Company established Shiroki Create Service Co.,
Ltd., located in Toyokawa City Japan.
North America
- Sales at Shiroki North America, Inc. (in the state of Tennessee)
were up by 5.9% or 1,498 million yen year-on-year, to 27,020 million
yen, hitting a record high for the fifth consecutive year. This
was mainly due to increased production volume of door sashes for
the Altima, Nissan Motor's model mass-produced in North America.
Nissan started producing the vehicle model in the fall of 2006.
As a result, the Company's operating profit was three million yen,
compared with last year's operating loss of 141 million.
- In December 2006 Shiroki-GA. L.L.C in Georgia expanded its plant,
while Shiroki-GT L.L.C. in Tennessee, Shiroki's third plant in North
America, started operations in March 2007 to cope with increased
production volume of Japanese automakers and respond to new orders,
taking advantage of their nearby locations. The Company has made
company-wide efforts to prepare for the production of door sashes
to be supplied to one of the best-selling mass-produced vehicle
models in North America, the Nissan Altima. Production started in
September 2006. The Company focused on increasing its production
capacity and gaining new orders to strengthen its business structure
in North America.
Asia
- Sales at Guangzhou Shiroki Corp. in China grew sharply, recording
2,324 million yen, or 4.97 times the previous record, up by 1,865
million yen year-on-year. This was mainly the result Toyota's launching
production of the Camry, to which the Company supplied products.
- In Thailand, Shiroki (Thailand), Co., Ltd. in Chonburi increased
sales year-on year by 934 million yen, or 39.9%, to 3,279 million
yen. This was mainly attributable to greater sales of the IMV, a
strategic vehicle destined for the global market, by Toyota Motor
in Thailand. As a result sales in Asia reached 5,571 million yen
(up 101.3% compared to those of the previous term), and operating
profit was 408 million yen. These were favorable results compared
to an operating loss of 156 million yen in the last fiscal year.
-China
- In connection with Toyota's launching production in Guangzhou,
China at Guangzhou Shiroki Corp. the Company increased the production
volume of door sashes and moldings in May 2006 while starting production
of window regulators. To deal with the increased production volume
in addition to new orders from Japanese automakers in China, the
Company started building a second plant within the premises of the
existing plant in November 2006, thereby strengthening both its
production and business structure in South China.
-Thailand
- Shiroki (Thailand), Co., Ltd. (Chonburi) continued dealing with
increased production volume of Toyota's strategic vehicle destined
for the global market, the IMV. In June 2006 the Company started
to supply door sashes, one of its major products, to Nissan Motor
in Thailand on an outsourcing basis to Nissan in order to strengthen
its business structure in the country.
-India
- In February 2007 the Company decided to invest in an Indian auto
parts maker, Technico Industries Ltd., located in Haryana. The Company
currently licenses various technology on window regulators to Technico,
aiming to strengthen its alliances with its business partners.
Accelerated outsourcing of parts produced in Japan
The Company will promote outsourcing of parts production in Japan.
Outsourcing to its group parts suppliers will be expanded to cover
a variety of products except for its three main products of door
parts, window regulators (devices to lift and lower windows) and
seat components, as well as mechatronics components related to leading
parts and electronic control. In view of a forecast of mid to long-term
deceleration in the domestic automotive market, Shiroki Corporation
will devote its management resources primarily to manufacturing
and development of its mainstay products. In Aichi and surrounding
areas where the company's main plants are located, The Company will
increase outsourcing to member companies of NS (New Shiroki) Association,
consisting of tier-2 and tier-3 suppliers. Outside of Aichi prefecture,
at Fujisawa plant in Fujisawa city, Kanagawa prefecture, which is
supplying mainly to Nissan Motor, Nissan Shatai, Hino Motors and
NHK Spring, Osaka plant in Ibaraki city, Osaka, whose major customers
are Daihatsu Motor and Mitsubishi Motors, and its subsidiary Kyushu
Shiroki Co., Ltd in Yahata Higashi-ku, Kita-Kyushu city, the company
will consider outsourcing to subcontractors belonging to other groups.
The Company is undergoing reorganization of domestic production
system by taking such steps as closure of its Toyota plant (Toyota
city, Aichi prefecture, the 3rd manufacturing section of Nagoya
plant) during fiscal 2007 and transfer of production of door sashes
to the headquarters plant in Toyokawa city and assembly of seat
components to its Nagoya plant (Toyota city), as well as easing
tight operation at the Osaka plant by increasing the production
capacity at Kyushu Shiroki. (From an article in the Nikkan Jidosha
Shimbun on Mar. 9, 2007)
R&D
- R&D expenses for the automotive
parts business in FY2006 were 2,142 million yen on a consolidated
basis.
Recent R&D achievements (Automotive Division)
Development of;
1. Next-generation seat tracks (power/manual) (both power and manual)
2. Next-generation power recliners
3. New wire-type regulators
4. New arm-type regulators
5. New door frames
Technological Alliances (as of March 2007)
- | Company (Country) |
Manufacturing Technology | Contract Period |
Licensing-in | Keiper-Recaro
GmbH & Co. (Germany) |
Seat recliners |
Apr. 1, 1998 - Mar. 31, 2008 |
Licensing-out | NHK Spring
(Thailand) Co., Ltd. (Thailand) |
Seat recliners Seat track |
Dec. 10, 1990 - Dec. 10, 2007 |
Summit
Laemchabang Auto Body Co. (Thailand) |
Door frames |
Feb. 21, 1994 - Dec. 31, 2007 |
|
Asan Co.,
Ltd. (Korea) |
Automotive door frames |
May 8, 2003 - Oct. 31, 2008 |
|
Cooperation | Brose Fahrzeugteile
GmbH & Co. (Germany) |
Window
Regulators Door systems Seat Adjusters & Others |
Feb. 14, 2001 - Feb. 13, 2008 |
Investment Activities
Capital investment made into the automotive
component business in FY2006 totaled 7,371 million JPY, mainly to
improve facilities to augment production volume, achieve cost reductions,
and prepare for the production launch of a new vehicle model.
Overseas manufacturing capabilities
-Thailand
The Company will introduce clean room engineering to its major overseas
plants. The company has already built and installed at its Toyokawa
Plant (Toyokawa City, Aichi Prefecture) a dust-free production line
for window regulators with the "anti-trap" mechanism developed
jointly with Brose Fahrzeugteile GmbH & Co. (Germany), paving
the way for improved production quality, including durability. Shiroki
intends to complete the installation of such "clean equipment"
at Shiroki Co., (Thailand) located in Amata Nakom City by the end
of August and to supply window regulators to Toyota Motor Thailand
for the "Yaris" (called "Vitz" in Japan). In
time with localization of the product, the company will extend application
of the system to China (in Guangzhou) and the U.S. (From an article
in the Nikkan Jidosha Shimbun on Sep. 1 2006)
-China
The Company announced that it will construct a second production
facility at its Chinese subsidiary in Guangzhou with an investment
of 350 million yen in a plant building. The additional factory will
be set up in the premises of Guangzhou Shiroki Corporation to manufacture
exterior auto parts including window regulators and moldings for
supply to Japanese affiliated automakers operating in China. The
construction is scheduled to be completed by June 2007 in preparation
for startup of the operation. Guangzhou Shiroki established a comprehensive
production line from stamping to assembly process for door sashes
and window regulators at the end of last year, and also added a
new production line in time for production launches at Nissan Motor's
local joint venture "Dongfeng Motor" and Toyota's local
joint venture "Guangzhou Toyota," to increase production
capacity of door sashes and moldings to 100,000 units a month respectively,
and window regulators to 40,000 units a month.(From an article in
the Nikkan Jidosha Shimbun on Aug. 4, 2006)
-USA
The Company announced plans to increase its U.S. production capacity.
It will enlarge its plant in Georgia to increase doorframe production
and purchase a closed plant of a local company in Tennessee to establish
the third U.S. plant for functional seat components production.
The total investment, excluding equipments and molds, will be limited
to approx. 1.1 billion yen. With these plans, the company aims to
respond to production expansion of its major client, Toyota, and
to new parts orders from Nissan for the volume production models.
(From a story in the Nikkan Jidosha Shimbun on May 13, 2006)
The Company announced that it has established its third plant in
the U.S.A., SWM-GT, L.L.C., as a fully-owned subsidiary of SW Manufacturing
Inc., Shiroki's another U.S. subsidiary that oversees the company's
operations in North America. The plant construction will begin in
August 2006 and the operation will start in January 2007. The total
investment will be 440 million yen. The new plant will have a workforce
of 80, comprised mainly of local nationals, and aims at generating
sales of over 1.7 billion yen in the first fiscal year. Starting
from January 2007, the new plant will produce mechanical parts for
automotive seats, such as seat recliners and adjusters, and parts
for doors, such as window regulators and door locks. The Company
already has overseas plants in Tennessee, Georgia, China (Guangzhou
Shiroki Corp.) and Thailand (Shiroki Corp. (Thailand), Ltd.). After
the addition of the new U.S. plant, it will have five overseas plants.(From
a story in the Nikkan Jidosha Shimbun on Jun. 22, 2006)
New equipment installation
Plant | Facilities | Estimated amount of investment (million yen) | Project Period | |
From | To | |||
Fujisawa
Plant - headquarters (Kanagawa Pref., Japan) |
Manufacturing equipment for new products | 578 | Apr. 2007 |
Mar. 2008 |
Nagoya
Plant (Aichi Pref., Japan ) |
Manufacturing equipment for new products | 1,694 | Apr. 2007 |
Mar. 2008 |
Nagoya
Plant No. 3 Production Section (Aichi Pref., Japan) |
Manufacturing equipment for new products | 316 | Apr. 2007 |
Mar. 2008 |
Toyokawa
Plant (Aichi Pref., Japan) |
Manufacturing equipment for new products | 1,281 | Apr. 2007 |
Mar. 2008 |
Osaka Plant (Osaka, Japan) |
Manufacturing equipment for new products | 156 | Apr. 2007 |
Mar. 2008 |
Prototype
Manufacturing Plant (Aichi Pref., Japan) |
Manufacturing equipment for new products | 15 | Apr. 2007 |
Mar. 2008 |
Toyokawa
Head Office (Aichi Pref., Japan) |
Testing
equipment and |
251 | Apr. 2007 |
Mar. 2008 |
Plant | Facilities | Estimated amount of investment (thousand USD) | Project Period | |
From | To | |||
Shiroki
North America, Inc. (Tennessee, USA) |
Manufacturing equipment for new products | 313 |
Jan. 2007 |
Dec. 2007 |
Shiroki-GA,
LLC. (Georgia, USA) |
Manufacturing equipment for new products | 776 |
Jan. 2007 |
Dec. 2007 |
Shiroki-GT,
L.L.C. (Georgia, USA) |
Manufacturing equipment for new products | 160 |
Jan. 2007 |
Dec. 2007 |
Guangzhou
Shiroki Corp. (Guangdong, China) |
Plant | 203 |
Jan. 2007 |
Dec. 2007 |
Manufacturing equipment for new products | 864 |
Jan. 2007 |
Dec. 2007 |