Kayaba Industry Co., Ltd. Business Report FY2006
Business Highlights
(in million JPY) | FY2006 | FY2005 | Rate of Change (%) |
Factors |
Overall | ||||
Sales | 356,083 | 290,455 | 22.6 | Total sales increased due to the substantial sales increase of industrial hydraulic equipments and the sales increase of automobile hydraulic snubbers. |
Ordinary income | 15,111 | 8,272 | 82.7 | Income increased due to a substantial increase in sales, steel price hikes being passed on to the product sales prices, cost reduction initiatives, and positive currency translation due to the weaker yen, etc. |
Current net income | 6,959 | 2,917 | 138.6 | |
Hydraulic products | ||||
Sales | 345,539 | 278,696 | 24.0 | Hydraulic snubbers: Profit
increased by 16.6%
year-on-year due to the increased sales of products
to be used for new automobiles manufactured in Japan whose
production volume increased supported by strong export growth,
as well as due to increased sales overseas in response to
Japanese automakers expanding their production volume outside
Japan, and increased sales of products used for the
after-market in Eastern Europe and North America. |
Operating profit | 20,213 | 12,921 | 56.4 |
New Subsidiaries
The Company announced to turn Takako Industries INC, which is
a manufacturer of components for hydraulic machinery located in
Seika cho, Kyoto Prefecture, and 55.9% owned by the Company, into
its wholly-owned subsidiary. It intends to bond relationship with
Takata closer by making the company its 100% owned affiliate with
the aim of fortifying competitiveness in the market of hydraulic
machinery. Following approval at Takako's extraordinary shareholders
meeting to be held on September 7, 2006, the transfer of stocks
is to become effective on October 1. The exchange ratio will be
32.049 shares of Takako to 1 share of the Company. (From an article
in the Nikkan Jidosha Shimbun on Aug. 25, 2006)
New Contracts
Audi (Germany) and KYB Suspensions Europe S.A. successfully developed
a smaller and lighter Dynamic Ride Control (DRC)-a special shock
absorber system that counteracts pitch and body roll movements-and
installed it on the Audi "RS4" and "RS4 Avant.
"The system was originally developed as "X-REAS"
by Yamaha Motor Co., Ltd., which offers the licensing to KYB Suspensions
Europe. The Toyota "4 Runner (Japanese model name: Hilux
Surf) and the Audi "RS6" have already used this X-REAS
technology, and the"RS4" is the third mass production
model to adopt the technology. With the X-REAS system, the diagonally
opposed shock absorbers are linked together hydraulically to control
flow of oil pressure. The absorbers installed on the right front
wheel and the left rear wheel, and those on the left front wheel
and the right rear wheel are linked together. (From an article
in the Nikkan Jidosha Shimbun on Jul. 13, 2006)
The Company delivered a system which consists of a steering gear
used for hydraulic power steering and a vane pump, to GM Holden
Ltd. in Australia. This is the first time for the Company to deliver
the system to Australia.
Business Plan
The Company plans to increase the shock absorber sales in Europe
by 20% from the previous fiscal year. KYB Europe GmbH, its subsidiary
in Europe, set up a large distribution base in the northwest of
Paris in April 2006 to reorganize its supply system intending
to increase sales, in addition to opening a representative office
in Moscow in January. By leading with sales expansion in Russia
and East Europe, the Company aims to increase its aftermarket
absorber sales across Europe by 700,000 units from 3.5 million
units in FY 2005. (From an article in the Nikkan Jidosha Shimbun
on Sep.15, 2006)
R&D
R&D Structure
-The Company conducted R&D activities mainly at its two technical
research institutes, focusing on basic technology and product
technology.
-The technical research institutes are mainly in charge of conducting
basic research and developing new products. The plant engineering
departments are in charge of development activities that improve
product appeal such as enhancing performance and reducing costs,
etc.
R&D Expenditure
-R&D costs at the hydraulic products division in fiscal year
2006 that ended March 2007 were 3,636 million yen.
Results of R&D Activities
Hydraulic snubbers
-The Company developed a tightly structured air suspension for
the Lexus. This air suspension can absorb the torsion generated
when the vehicle is being steered. This air suspension also
improves steering performance and vehicle maneuverability,
and in addition, needs less space where it is installed on the
vehicle.
Hydraulic equipment
-In the area of production engineering, the Company established
an assembly line for CVT (Continuously Variable Transmission)
vane pumps at KYB Kanayama Co. Ltd. This line is intended to improve
the reliability of work done in automated processes as well as
control contamination and traceability. In the cylinder bottom
welding process, which had needed residual heat to prevent the
weld from cracking, the Company made use of technology which prevents
the weld from cracking without needing residual heat. The company
put this technology to use at all the assembly lines that produce
high-pressure cylinders. In addition, the Company developed a
new system that uniformly manages production records for hydraulic
motors, from the time materials are received up until the motors
are shipped. And for its main product especially, base plates,
the Company marks a two-digit code with laser beam that enables
it to manage the production record of each piece.
Other equipments
-The Company developed and marketed a drive recorder it calls
"Kurumame", which graphically records the conditions
before and after accidents occur, helping to analyze the causes
of the accidents and contribute to safer driving.
R&D activities
-In the area of product technology, the Company developed an automobile
hydraulic pressure active stabilizer system which controls the
degree of both front and rear rolling resistance individually.
The system responds according to what the the conditions were
at the time the vehicle was in motion, improving kinematic performance
and riding comfort.
-In the area of production engineering, the Company focused on
the development of DLC (Diamond-Like Carbon) coating technology,
which is designed to reduce frictional force in areas that are
supposed to glide effortlessly. This new technology is four times
more durable than conventional technology.
-The Company conducted joint-research
activities with Tokyo University and Toyota Motor Corporation
on suspension using electromagnetic power and energy regeneration.
Automobile-related licensing agreements (as of March 2007)
Contract party | Country | Subject | Details | Term | ||||||
Kayaba-UMW Malaysia Sdn. Bdn. | Malaysia | Shock absorbers for automobiles, front forks and oil cushion units for two-wheeled vehicles |
|
Oct. 13, 1993 - Oct. 12, 2008 |
||||||
P. T. Kayaba Indonesia | Indonesia | Shock absorbers for automobiles, front forks and oil cushion units for two-wheeled vehicles |
|
Mar. 18, 1994 - Jan. 31, 2008 |
||||||
Zhuzhou Nanfang Yamaha Shock-Absorber Co., Ltd. | China | Front forks and oil cushion units for two-wheeled vehicles |
|
Sep. 15, 1995 - Sep.14, 2010 |
||||||
KYB (Thailand) Co., Ltd. | Thailand | Shock absorbers for automobiles, front forks and oil cushion units for two-wheeled vehicles |
|
Feb. 01, 1996 - Jan. 31, 2008 |
||||||
KYB Manufacturing North America, Inc. | USA | Shock absorbers for automobiles |
|
Oct. 01, 2001 - Sep. 30, 2007 |
||||||
Gabriel India Limited | India | Shock absorbers for automobiles |
|
Feb. 20, 2003 - Feb. 19, 2008 |
||||||
KYB Steering Spain, S.A. | Spain | Automobile hydraulic equipment |
|
Jan. 01, 2004 - Dec. 31, 2010 |
||||||
KYB Suspensions Europe, S.A. | Spain | Shock absorbers for automobiles |
|
Oct. 01, 2004 - Sep. 30, 2009 |
Investment Activities
The total capital investment planned for fiscal year 2007 that ends March 2008 is 20 billion JPY, out of which 19.7 billion JPY is planned to be invested in the hydraulic products business.
Domestic Investments
The Company will double production of hydraulic control pumps for continuously variable transmissions (CVT) within the next three years and intends to establish a capacity to produce 1.8 million pumps for the CVT. The Company plans to invest about 7 billion yen for fiscal 2007 including funding for improvement of productivity. The Company's subsidiary, KYB Kanayama located in Gero City, Gifu Prefecture is increasing its production capacity of such pumps (From an article in the Nikkan Jidosha Shimbun on Nov. 29, 2006)
Overseas Investments
The Company will expand the plant of KYB Manufacturing North America Inc.(KMNA), its U.S. subsidiary, producing and selling hydraulic shock-absorbing products. It plans to expand the plant to enhance its production capacity so that it can boost production volume in response to an increasing demand in North America from Japanese auto manufacturers including Toyota and Honda. The Company will additionally build a new plant, which covers 24,553 square meters, within its existing plant facility (Franklin, Ind.). With this extension the Company will increase its annual production capacity at KMNA by 3 million units to 9.6 million units. The Company will invest a total amount of 27 million USD (approximately 310 million JPY). The new plant will be officially opened in November 2007. (From a press release by the company on Dec. 7, 2006)