JTEKT Corporation Business report FY2007
Business Highlights
Financial Overview
(in million JPY) | FY2007 | FY2006 | Rate
of change (%) |
Factors |
Overall | ||||
Sales | 1,157,594 | 1,025,297 | 12.9 | Sales increased due to the Company's enhanced development capabilities for creating technology, and its excellent product quality. This is also the result of improving the efficiency of its production and sales operations. |
Operating income | 77,650 | 64,630 | 20.1 | Income rose since higher materials prices were offset by increased sales. |
Ordinary income | 72,896 | 66,968 | 8.9 | Income rose since increases in materials prices and a rise in depreciation costs due to the revision of the corporate tax system were offset by strong sales. |
Current net income | 43,446 | 44,900 | (3.2) | - |
Mechanical Components Division | ||||
Sales | 954,968 | 826,045 | 15.6 | Since sales of steering, bearing and powertrain parts were brisk both in and outside Japan, mainly in Europe and Asia, sales increased. |
Operating income | 59,569 | 43,665 | 36.4 | - |
Contracts
The Company announced that its "rack-cross electric power steering (RC-EPS)" was adopted by General Motors Corporation (GM) for its full-size SUVs (sport utility vehicles), Chevrolet Tahoe Hybrid and GMC Yukon Hybrid. It is the first electric power steering (EPS) system adopted by full-size SUVs. Its RC-EPS is equipped with high-output compatible motors designed exclusively for the product and a two-speed transmission with ball screws and bevel gears, thus featuring higher output and efficiency. This has made it possible for large vehicles with a weight of over 3 tons to adopt the new technology. (From an article in the Nikkan Jidosha Shimbun on Jan. 23, 2008)
New Incorporations
-India
In Jul. 2007, the Company established a new joint venture, JTEKT Sona Automotive India Ltd. (JSAI), in Haryana, India for the manufacture of electric power steering in partnership with Sona Koyo Steering Systems Limited (Sona Koyo). Manufacturing operations at JSAI are scheduled to start in Jan. 2010.
Sona Koyo of India has formed a joint venture with American Axle & Manufacturing Holdings, Inc. (AAM). The new company, AAM Sona Axle Private Limited (AAM Sona Axle), will manufacture and sell light truck, passenger car, and SUV axle assemblies for the India market.
Business Plan
The Company will enter the continuously variable transmission (CVT) chain market, following a successful development of highly efficient, large torque compatible involute chains with the aim to commercialize the projects by 2009 and achieve annual sales of one million units or 10 billion yen in 2012. In response to automakers' shifting to CVTs from automatic transmissions to improve fuel efficiency, It will designate CVT chains as its major business next to bearings and steering systems. The newly developed involute chain features spiral form, which has not yet been commercialized in and outside Japan. They are capable of reducing noise, which was the weak point of conventional CVT chains, and can be used in wider range of torque, more than double the upper limit of torque (approx. 350 N.m) for metal belts. They improve fuel efficiency by four to five percent compared with conventional CVTs. (From an article in the Nikkan Jidosha Shimbun on Apr. 9, 2007)
The Company will enhance the partnership with Fujikiko Co., Ltd., a group member supplier manufacturing steering systems and sheet parts, for expanding the power steering business. It will work on downsizing and upgrading performance of next-generation electric power steering systems (EPS). As for a column type EPS, which is expected to show a rapid rise in demand in the future, the company will endeavor to enhance its product competitiveness by integrating the system with supporting parts of the column. Taking advantage of collaboration with Fujikiko, which has a long business relationship with Nissan, the Company will seek to explore new markets and customers. (From an article in the Nikkan Jidosha Shimbun on Oct. 29, 2007)
R&D
R&D Structure
-R&D facilities in Japan
Facility |
Location |
R&D center | Nara Pref. |
Osaka Pref. | |
Aichi Pref. |
R&D Expenditure
(in million JPY) |
FY2007 | FY2006 | FY2005 |
Overall | 30,857 | 29,957 | 24,718 |
R&D activities (FY2007)
Steering Division
The Company developed for the first time in the world an electric
power steering system for large-sized SUVs and pickup trucks of
three tons or more, on which hydraulic power steering systems are
being installed. The new steering system was launched in the North
American market in December 2007. This will make the Company the
only supplier of a complete lineup of electric power steering systems,
from those for mini cars up to those for large-sized SUVs and pickup
trucks.
In December 2007 the Company started commercial production of variable
flow control (VFC) pumps in the North American market. These energy-saving
pumps are designed for conventional hydraulic power steering systems.
The flow in these pumps can be controlled depending on the driving
condition, thereby reducing energy loss by half while improving
fuel efficiency.
The Company has developed a hall IC torque sensor for electric power
steering (EPS) and will expand the application to EPS. The new sensor
will work efficiently in a high-temperature engine room to ensure
a stable steering operation. It uses highly-functional hall ICs
with built-in digital computer, nonvolatile memory and thermal compensator,
which has made it possible to check engine torque more accurately
and reduce its property fluctuation for changes in temperature by
30% compared to traditional torque sensors. The new product complies
with future European safety standards to be enacted starting 2010.
It contains two IC chips and monitors their output variance, thus
improving capability to detect malfunctions. (From an article in
the Nikkan Jidosha Shimbun on Jun. 26, 2007)
Bearing & Drivetrain Components Division
-Bearing
The Company announced a development of a new electric pump for an
idling stop system. The new product is the smallest in the world
in size among electric pumps of equal performance, and it is carefully
designed to work very efficiently in a certain oil pressure range,
in which the device is used frequently. The company succeeded in
making the new product 60% smaller than traditional-type pumps by
adopting a brush-less and sensor-less motor and integrating a controller
and a pump. The supplier also succeeded in improving efficiency
of the pump by 5 to 10% and reduced the burden on the battery by
optimal designing. By application of this new technology to hybrid
vehicles that require electric pumps while running on motors, in
addition to models with the idle stop mechanism, it aims to generate
sales of 700 million yen in 2012. (From an article in the Nikkan
Jidosha Shimbun on Jun.1, 2007)
The Company has developed a new "RD3 "bearing seal for
automotive air conditioning compressor pulleys that boasts low torque
and outstanding sealing capability and has begun mass-production.
It intends to proceed with standardization of RD3 seal and expand
the application of the seal to idler bearings and other bearings
with outer ring rotation. (From a press release on Sep. 25, 2007)
The Company has developed a new lightweight hub unit for compact
vehicles. The new hub unit offers a 30 percent reduction in product
weight, without compromising on the level of rigidity and strength
of conventional hub units. It achieved this by using its CAE (computer-aided
engineering)-based design method for developing an axle assembly,
which is composed of a hub unit, a brake drum, and a wheel. The
company manufactures and sells weight-saving hub units targeting
the compact vehicle segment; it aims to generate 3 billion yen per
year through this business by 2011. (From an article in the Nikkan
Jidosha Shimbun on Dec. 15, 2007)
The Company has developed a thrust needle bearing with considerably
reduced rotational torque for automotive transmissions. This new
low-torque bearing has approximately 50% less rotational torque
than conventional bearings, which helps improve vehicles' fuel efficiency.
It focused on the improvement of sliding resistance between the
roller end and the retainer pocket face. Surface reforming treatment
was executed for achieving exceptionally lower torque; a convex
configuration was strategically applied on the retainer pocket face,
which enabled a 50% reduction in rotational torque while maintaining
long service life, high-speed rotation, strong friction resistance
properties equivalent to those of the conventional products. With
the introduction of low-torque thrust needle bearing, the Company
aims to boost its total sales by 1.2 billion yen in 2012. (From
a press release on Mar. 14, 2008)
The Company developed a new, continuously variable transmission
(CVT) chain (called the JTEKT involute chain), which enhances fuel
efficiency by 4-5% compared with conventional metal belts. Development
is underway for commercialization.
The Company, in working on developing a hub unit with a sensor capable
of detecting tire force, also started developing vehicle safety
control technology utilizing its expertise to detect the force
of tires.
The Company developed compact
needle bearings that are designed for planetary wheels. These new
bearings have product lives that are eight times longer than those
of existing bearings.
-Drivetrain
The Company developed new compact torque sensors for center differentials.
These sensors are designed to be mounted on the highest class of
hybrid vehicles in Japan.
The DKC (diamond like carbon)-Si layer technology that the Company
developed for electromagnetic clutches used on 4WD couplings (ITCCs),
were not only made compact but also were designed to make high-performance
ITCCs that will contribute to higher fuel efficiency.
Investment Activities
- |
FY2007 | FY2006 | FY2005 |
Overall | 58,912 | 60,303 | 43,013 |
Mechanical Components Division | 54,411 | 53,053 | 37,995 |
Overseas Investments (FY2007)
-India
In Jul. 2007, the Company established a new joint venture, JTEKT Sona Automotive India Ltd. (JSAI), in Haryana, India for the manufacture of electric power steering in partnership with Sona Koyo Steering Systems Limited (Sona Koyo). Manufacturing operations at JSAI are scheduled to start in Jan. 2010. The Company owns 51% of the joint venture, and Sona Koyo (also is located in Haryana and in which the Company holds 20.1%) owns 49%. The total amount of investment in JSAI is approximately 3.5 billion yen, and sales are projected to reach approximately 9 billion yen in 2010. (From a press release on Oct. 22, 2007)
Sona Koyo of India has formed a joint venture with American Axle & Manufacturing Holdings, Inc. (AAM). The new company, AAM Sona Axle Private Limited (AAM Sona Axle), will manufacture and sell light truck, passenger car, and SUV axle assemblies for the India market. The corporate headquarters of AAM Sona Axle will be located in Pune, India, and a new manufacturing facility will be constructed in north India. The facility is expected to launch in 2008 with the production of light vehicle axles for Tata motors. (From a press release on Oct. 30, 2007)
New Equipment Installment
Plant (Location) |
Type of facility | Estimated amount of investment (in million JPY) |
Project Period | |
From | To | |||
Kokubu
Plant (Osaka, Japan) |
Manufacturing facilities for mechanical components | 3,900 | Apr. 2008 | Mar. 2009 |
Tokushima
Plant (Tokushima, Japan) |
Manufacturing facilities for mechanical components | 3,600 | Apr. 2008 | Mar. 2009 |
Kagawa
Plant (Kagawa, Japan) |
Manufacturing facilities for mechanical components | 2,900 | Apr. 2008 | Mar. 2009 |
Daibea
Co., Ltd. Head Office & Sakai Plant (Osaka, Japan) |
Manufacturing facilities for mechanical components | 4,700 | Apr. 2008 | Mar. 2009 |
Koyo Corporation
Of the U.S.A. (South Carolina, USA) |
Manufacturing facilities for mechanical components | 3,300 | Jan. 2008 | Dec. 2008 |