TRW Automotive Business Report FY2009

Business Highlights

Financial Overview

(in million dollars)
  FY2009 FY2008 Rate of change
Sales 11,614 14,995 (22.5) -
Net earnings 55 (779) - -
Chassis Systems
Sales 6,819 8,505 (19.8) -The decrease in sales was driven primarily by lower volume and, to a much lesser degree, price reductions provided to customers, which combined totaled $1,246 million.

-The lower volume was attributed to a decline in light vehicle production volumes in all major geographic regions.

-Foreign currency exchange also had a net unfavorable impact on sales of $443 million.
Occupant Safety Systems
Sales 2,893 3,782 (23.5) -The decrease in sales was driven primarily by lower volume and, to a lesser degree, price reductions provided to customers, which combined totaled $661 million and the net unfavorable impact of foreign currency exchange of $240 million.
Sales 588 871 (32.5) -The decrease in sales was driven primarily by lower volume and, to a much lesser degree, price reductions provided to customers, which combined totaled $263 million, and the net unfavorable impact of foreign currency exchange of $57 million.
Automotive Components
Sales 1,314 1,837 (28.5) -The decrease in sales was driven primarily by lower volume and, to a much lesser degree, price reductions provided to customers, which combined totaled $405 million and the net unfavorable impact of foreign currency exchange of $143 million.


-The Company supplies its Active Control Retractor seat belt system, ACR2, for the new Hyundai Equus. The production has started in Asia and Europe. Compared to its predecessor, the new system is significantly reduced in both size and weight. (From a press release on Apr. 23, 2009)

-The Company supplies Daimler AG with its motor pump unit as part of the Electrically Powered Hydraulic Steering (EPHS) system on selected new Mercedes-Benz models. (From a press release on Sep. 10, 2009)

-The Company announced production milestone - its ten millionth Electric Parking Brake (EPB) motor-on-caliper unit at its plant in Koblenz, Germany. The Company started marketing the EPB system in 2002 which has since been launched on the Audi A4, A5, VW's Passat and Touran, BMW Z4 and more. (From a press release on Oct. 20, 2009)


-TRW Automotive U.S. LLC, a subsidiary of the Company, announced the acquisition of Michelin North America Inc.'s stake in the EnTire Solutions, LLC joint venture. The Company and Michelin established the joint venture in 2003 to develop and manufacture direct tire pressure monitoring systems. (From a press release on Jan. 15, 2009)

Outlook for FY2010

-The Company expects full year 2010 sales to be in the range of $12,300 million to $12,900 million, including first quarter sales of approximately $3.4 billion. These sales figures are based on expected 2010 production levels of 10.8 million units in North America and 16.0 million units in Europe, and take into consideration its expectation of foreign currency exchange rates.


R&D Expenditure

-Total research, development and engineering costs as a percentage of sales were Approx. 6% in FY2009.

R&D Facilities

(As of Dec. 31, 2009)

  North America Europe Asia
Chassis Systems 3 4 2 1
Occupant Safety Systems 2 3 - -
Electronics 1 - - -
Automotive Components 1 - - -

-In Apr. 2009, the Company has announced the opening of a new test track in Heihe in the northern region of China. The facility offers comprehensive product development and validation during the winter season, offering a variety of track surfaces which are designed to test active safety systems such as advanced braking and steering systems and integrated vehicle control and driver assist technologies. The facility is situated on approximately 350 acres, comprised of around 320 acres of lake tracks and 30 acres of land tracks. (From a press release on Apr. 30, 2009)

-In Nov.2009, the Company has set up its second North American Driver Assist Systems (DAS) Engineering Center at the Company's Livonia, Michigan headquarters in the United States. The new center will focus on the development and testing of radar applications. This facility will work closely with the Camera Development Center located in Farmington Hills, Michigan, and with the North America braking technical center in Livonia. (From a press release on Nov. 11, 2009)

Product Development

Active Head Restraint (AHR) system
-TRW Vehicle Safety Systems Inc., a subsidiary of the Company, has introduced a new Active Head Restraint (AHR) system utilizing a mechanical concept that is lighter, less complicated and uses fewer components than competing systems on the market. The TRW AHR can be integrated into any headrest height adjuster. In addition, this system can help to reduce the chances of whiplash forces acting on the occupant. (From a press release on Jan. 14, 2009)

Camera and multi-sensor unit
-The Company developed a camera and multi-sensor unit. Beyond automatic on-off headlamp control the camera can also determine in low light conditions if other traffic is in the vicinity and if not can automatically switch on the high beams. In addition, the system will automatically engage the windshield wipers and can vary the speed of the wiper motor depending on the amount of moisture detected by the optical rain sensor. Another feature is a humidity sensor that detects the amount of humidity in the vehicle interior and can activate the blower motor within the HVAC system to keep the windshield defogged. (From a press release on Aug. 24, 2009)

Driver airbag module
-The Company developed a new driver airbag module which is over 50 percent smaller than conventional driver airbag modules. The weight reduction is achileved by applying new DI-10 inflator. (From a press release on Dec. 1, 2009)

IAA 2009

-The Company's stand focuses on these three key areas which underpin Cognitive Safety: "Advanced Thinking", "Green Thinking" and "Smart Thinking".

Advanced Thinking
-Enhanced video camera sensor to support lane departure warning and lane keeping systems, forward collision warning, forward distance indication, traffic sign recognition, high/low beam control and pedestrian detection.

-Pre-Crash Side Impact System: Side impact sensors supporting blind spot warning and enhancing airbag functionality.

-GPS data being used for curve prediction and linked to ACC and video.

-Automatic Emergency Braking (AEB) and Collision Mitigation Braking (CMB): combines forward looking radar and video systems to provide autonomous emergency braking if a collision becomes unavoidable. AEB is intended for higher speed driving and CMB for city driving conditions.

-Steering Torque Control: Combining Electronic Stability Control (ESC) with Electrically Powered Steering (EPS) to provide oversteer and understeer support.

Smart Thinking
-Next generation Airbag Control Unit (ACU) with integrated inertial sensors - eliminating the need for a stand alone inertial sensing module.

-Next generation Slip Control Unit with integrated inertial sensors - eliminates components and can thereby realize significant cost savings.

-Initial Safety Domain ECU (i-SDE) concept - part of the Company's next airbag platform which allows for the integration of a range of electronic control functions for active and passive safety.

-ACR2 Basic - a new, cost optimized active seatbelt retractor offering a simplified electronic architecture due to its integration with the airbag control unit.

-Integrated Electric Park Brake (EPBi) - eliminates the requirement for a separate ECU due to its integration with the Electronic Stability Control ECU.

-New DI-10 driver airbag module and SHI2 curtain airbag module realizing 50% weight savings over previous technologies.

-Scalable 24 GHz mid range radar supporting distance and collision warning, collision mitigation braking, follow to stop adaptive cruise control ("ACC"), activation of reversible restraint systems and braking.

-Scalable ACU - The Company's low cost airbag control unit for emerging markets can be adapted within a platform to offer two options - standard and enhanced in order to satisfy domestic and export aspirations.

Green Thinking
-Braking: The Company's Electronic Stability Control-Regenerative (ESC-R) and Slip Control Boost (SCB) are compatible with regenerative braking systems for HEVs.

-Steering: The Company's Electric Powered Steering and Electrically Powered Hydraulic Steering systems offer considerable fuel/emission benefits.

-Driver Assist Systems: Adaptive Cruise Control, Lane Guide and systems linked with GPS data all have a positive impact on fuel consumption.

-Tire Pressure Monitoring Systems (TPMS) inform the driver when tires are under inflated to improve rolling resistance and reduce fuel consumption by up to 2%.

-Climate Control: The Company's Efficient Comfort Control system minimizes energy draw on vehicle powertrains - contributing up to 5% fuel efficiency gains.
(From the Company's brochure of Frankfurt Motor Show 2009)

Investment Activities

Joint Ventures

(in which the Company has a 49% or greater interest)

Company Location Products Ownership
SM-Sistemas Modulares Ltda. Brazil Brake modules 50
Shanghai TRW Automotive Safety Systems Company Ltd. China Seat belt systems, airbags and steering wheels 50
CSG TRW Chassis Systems Co., Ltd. China Foundation brakes 50
Brakes India Limited India Foundation brakes, actuation brakes, valves and hoses 49
Rane TRW Steering Systems Limited India Steering gears, systems and components and seat belt systems 50
TRW Sun Steering Wheels Private Limited India Steering wheels and injection molded seats 49
Mediterranea de Volants, S.L. Spain Leather wrapping for steering wheels 49