Mecaplast S.A.M. Business Report Until FY ended Dec. 2013

Business Highlights

Recent Years

Financial Overview

-Sales for FY ended December 2012 was EUR 662 million, which reduced by 4.3% year-on-year.
-Sales ratio by geographic area was 53% for France/Monaco and 47% for International.
-Sales ratio by business sector was 65% for Car body and 35% for Engine.

Overseas bases

-In 2012, the Company opened two new production plants in Serbia (Zrenjanin) and in China (Yantai), and one research center in Turkey (Gebze). The Company is in advanced talks with a partner to establish JVs in Northern China and in the United States. (From an article in the Nikkan Jidosha Shimbun on Apr. 3, 2012)


-In 2012, the Company will deliver the following components for Fiat "500L" (design code 330) from its new plant in Serbia.
Exterior: black high gloss pillars (A, B, C), cowl grill, trunk light finisher, tailgate trim, body side moulding
Interior: pillars (A, B, C), package tray support, tailgate trim.
Engine: Air filter
(From an article in the Nikkan Jidosha Shimbun on Apr. 3, 2012)

-In 2010, the Company supplies body related parts for the "Renault Megane Coupe Cabriolet", which debuted at 2010 Geneva Motor Show. All parts have been developed in the site of Izernore, France. The production began in January 2010 at four plants (Vire, Sainte Marguerite, Precigne and Strasbourg) in France. The volume is 160 vehicles per day. (From a press release on March 5, 2010)

-In 2010, the Company supplies its indicator strip, front lower panel and aluminium roof bars for the "Dacia Duster", new SUV debuted at 2010 Geneva Auto Show. These parts were developed in the sites of Izernore and Vire in France and at the facility in Gebze, Turkey. The production began in January 2010 at the plant in Gebze. The volume will be 230 cars per day. The roof bars will be manufactured at the site in Vire, then assembled with plastic feet in Gebze. This is the first time that Mecaplast will provide roof bars with plastic feet to Renault. (From a press release on March 5, 2010)

-The Company announced that it supplies the cowl and door protections strips functions for the "Citroen C3 Picasso". The cowl functions are produced in the Zebrak site in the Czech Republic while the door protection strips are manufactured in Pardubice, Czech Republic. The C3 Picasso will be produced until 2015. (From a press release on Mar. 16, 2009)

<2008 and before>
-The new 1.6l Turbo Direct Injection petrol engine was named International engine of the year for 2007 in the 1.4l -1.8l category. This family of Prince engines equips the new BMW "MINI" and PSA A "207" and B "308"segment vehicles. The Company has been selected as supplier for air filters, cylinder head covers, and other components for the Prince engine. (From a press release on May 21, 2008)

-In Jan, 2007, the Group stated in its press that it was manufacturing a large number of parts for the interior, exterior and engine compartment for the 7-seater version PSA Citroen "C4 Picasso".

-In Mar. 2005, the Company announced that it was awarded an agreement to supply engine parts and interior trims for Aygo, Peugeot "107" and Citroen "C1" that are produced by Toyota Peugeot Citroen Automobile. Products to be supplied under the agreement are diesel engine components, gasoline engine components and interior trims, which are produced at Lens, France, TBMECA in Poland, a joint venture between Toyota Boshoku and Denso, and Zebrak and Pardubice in Czech respectively.

Joint Ventures

-In 2012, the Company sold 24.9% of its 50% shares in TBMECA Poland Sp.z.o.o. to Toyota Boshoku Europe N.V. TBMECA is a joint venture among the Company, Toyota Boshoku Europe and Denso International Europe. It produces and sells filters and powertrain components. The deal raised Toyota Boshoku's stake in the Polish joint venture from 30% to 54.9%, giving it a controlling interest in the company. (From an article in the Nikkan Jidosha Shimbun on Dec. 18, 2012)

-In 2004, the Company and the Chinese company Huaxiang created a 50/50 joint venture in Ningbo.

-In 2003, Toyota Boshoku, Denso, and the Company announced that they would establish TBMECA Poland Sp. Zo. O, a production company for engine-related parts, at Legnica, Poland. TBMECA Poland was established solely by the Company in October 2003 and Toyoda Boshoku and Denso will make an additional investment in the company around February 2004. After the investment, TBMECA Poland will be capitalized at EUR 3 million with 30% by Toyoda Boshoku, 20% by Denso, and 50% by the Company. Its production items consist of cylinder head covers, intake manifolds, air filters, oil filters, and other engine-related parts. Products will mainly be supplied to Toyota's European bases. TBMECA Poland plans to start production in December 2004.


-In Mar. 2003, the Company announced that it would acquire a French vehicle parts manufacturer Aries, for an undisclosed sum, following a decision by the French commercial court of Paris, the French News Digest reported. Aries was put into receivership on Nov. 25, 2002. The Company will take control of four of the five Aries plants in France and all the subsidiaries abroad, except the one in Spain. The company will employ some 90% of the 2,000 employees at Aries. The Company will re-employ some 50% of the workforce at the headquarters in Poissy, near Paris but will close the factory in Izernore, southeastern France and transfer production to other factories.

-During FY2002, the Company purchased the Neyr group. NEYR, formed in 1979, is a French-based group of companies specializing in plastic injection molding for the automotive, computer, domestic-appliance and electro-mechanical industries. The group has a turnover of FRF 1.65 billion for 1999. The automotive division generates 75% of the total sales.


-In July, 2013, the Company announced that Mecaplast India, based in Chennai, has been honored by Toyota with the Innovation Award for the development of Its cylinder head cover.


R&D Structure

-In 2013, 300 engineers and technicians work with customers worldwide.

-In 2013, the Company spent 4.5% of its turnover on R&D activities.

-In 2013, the Company has 3 Skills Centers, 1 Acoustic Center and 10 Technical Centers. 

-Three development centers (Monaco, Lens, La Braconne) follow up projects after assignment to provide the Company's manufacturing units with turnkey projects. The centers are completely linked to each other, its customers and suppliers by data processing in order to develop its applications in its customers language more efficiently.

-Further, the Company can validate Its concepts before delivery by using three laboratories and also especially the test engine center in Lens. On top of those internal resources, the Company is a major partner in two national technical centers: Critt M2A (engines performance and acoustic management) CAH (auto, interior, acoustics), which allows access to state of the art equipment. All of the Company's technical methods are supported with rigorous project methodology, which satisfies the strictest existing quality standards.

R&D Activities

-On going projects in 2013;
  • Weight reduction: Use of new materials, new injection process and new way of modeling and design. (ALMA, PLUME, ENJOY project)
  • Use of recycled materials: Recycle target of PP, PA etc. is 17%. (RECYCLON project)
  • Cleanliness of engine parts
  • Material standardization
  • Product development for Trucks
  • Development of thermoplastic racks for electrical vehicle (OPERA4FEV)
-In Sept. 2011, the Company initiated a collaborative project OPERA4FEV, OPerating Energy RAck For Full Electric Vehicle, which focuses on the development of a thermoplastic rack with batteries for electric vehicles. This project involves a consortium of 9 partners from 5 European countries, including Centro Ricerche Fiat and FAM Automobiles, and has a total budget of EUR 7 million. The project started in September 2011 for a total period of 42 months. The OPERA4FEV project aims to develop thermoplastic battery racks on two functional demonstrators: one for a large scale vehicle from Fiat and one for the F-City from FAM. The main issues relative to OPERA4FEV project include: 50% reduction of number of components and 30% weight reduction on components (cells excluded). (From a press release on September 29, 2011)

-In Oct. 2007, the Group released the newly developed Filleas (Fiber Localization for Lightweight Extended Acoustic System), an acoustic solution for the passenger's comfort and for the diminution of the noises generated. Filleas is ecologically friendly because it's composed of a mixture of fibers and recycled solid particles. It contains residues of used tires, automotive waste, various industrial waste, recycled fibers mainly issued from used clothes, in other words, a major proportion of recycled material; up to 95% in weight. Moreover, the major technology of Filleas in regard to the other acoustic solutions is to ensure the insulation inside the cab interior and the ambient noises absorption inside the vehicle at the same time.

-In Dec. 2006, the Group announced a new technology: the 3D Painting to provide carmakers with new decors. The principle is that magnetic particles in suspension in paint, under the influence of a magnetic field, re-orient and create patters. The progressive change of direction provides a depth effect and thus the impression of contours and 3 dimensional images. The patterns can vary in shape and color.

-In Apr. 2006, the Group announced that the new family of Prince engines, which comprises five versions, has been developed conjointly by BMW and PSA Peugeot Citroen, and will equip several vehicles of the two car makers. The Group is chosen to produce plastic parts of the air intake module for the turbo charged petrol engine 140 hp (P105 engine) and 170 hp (P125 engine). The production of the parts will start at the sites of Lens and Villers-Bretonneux in the first quarter of 2006. The Group uses two fabrication processes: the infrared welding, called "freeweld", for the manifold and gas injection for the cam cover.

Investment Activities

Investments Outside Monaco

-In 2013, the Company expanded the plant in Peterlee in England.

-In Nov. 2011, the Company announced that it will open a new plant in Zrenjanin, Serbia. The new plant will develop and manufacture interior, exterior and engine parts for Fiat's small vehicle. The Company is using an existing 3,200 square meters factory, and it will add a 2,500 square meters shop floor. Construction of the new shop floor began in June 2011, and start of production will be May 2012. The Company has three factories in Central Europe: Zebrak and Pardubice in the Czech Republic and Legnica (Joint Venture) in Poland. (From a press release on November 10, 2011)

-In 2014, the Company opened a new plant in Shenyang, China.

-In 2012, the Company opened a new plant in Yentai, China.

-In 2010, the Company announced a plan of growth in China. Currently the company's turnover is EUR 40 million in China and it will be more than twice in 2014, that means EUR 100 million, approximately 20% of the Company's turnover. The Company made Its first steps in China in 1997 with the creation of a joint venture factory in Wuhan. In 2002, the Group created a plant and a technical center in Shanghai. This growth will go through the opening of a third factory in the South in a short term, and then a bit further, a fourth in the North. In China, the Group manufactures mainly engine parts including air admission line, cam cover and manifold, supplying them to local customers such as Shanghai Automotive Industry Corporation (SAIC), Shanghai General Motors SGM), and Dongfeng Peugeot Citroen Automobile (DPCA). The Company also manufactures body products such as internal trim, console, cowl grille, and others. (From a press release on September 21, 2010)

-In Jul. 2005, the new Shanghai facility opened at the same site where the Group holds its Chinese head office, Mecaplast Shanghai. The new facility will start production of more than 60 new parts in 2006. With the currently existing Wuhan Mecaplast, a joint venture of 70% the Group and 30% Ya Zhong, the Group plans to reinforce its business activities and development in Asia.

-In Jun. 2010, the Company set up a new subsidiary Mecaplast India Pvt Ltd. in Chennai, India - its first production site in the nation. Located near Ford, Renault-Nissan, BMW and Hyundai facilities, the plant currently employs 40 people. It is able to meet production requests for engine and bodywork plastic parts for the local and international market. As a supplier for Ford engine modules DV4, the site already started the production of cam cover, air intake manifold, air filter, resonator, diesel filter and belt cover. Mecaplast India expects to see its turnover double in two years. (From a press release on June 14, 2010)

-In Dec. 2006, the Company announced to open a new office near Detroit, the third establishment of the Company on the American continent which also has production units in Mexico and Brazil. This office enables the Company to:
1. Locally manufacture GM parts, including engine parts GMX 381 and Epsilon 2 (air filters and clean side hose) and interior parts GMT 166/381 (interior trim).
2. Develop new partnerships with customers and increase sales in North and South America, by working with the existing production units located in America.
3. Create Technical Units to develop the projects on the Americas area.

-In early 2006, the Group opened its Japanese set-up in Tokyo, Mecaplast Japan, aiming at promoting the Group with Japanese car makers. This office will strengthen its relations with those who already are its customers (Toyota, Nissan, Honda, Mitsubishi and Isuzu). On the other hand, it will work on establishing new partnerships with other carmakers such as Suzuki.