KASAI KOGYO CO., LTD. Business Report FY2008

Business Highlights

Financial Overview (in millions of JPY)
  FY2008 FY2007 Rate of
Change (%)
Factors
Sales 122,452 144,888 (15.5) -Decline in sales at its major customers in Japan and North America
Operating income 1,936 3,894 (50.3) -Decline in sales
Ordinary income 806 3,465 (76.7)
Net income (3,543) 1,302 - -A re-assessment and review of deferred tax assets and other items was conducted.


Developments Outside Japan
-In Jul. 2008, the Company announced that it would acquire a majority stake in P.T. Oriental Manufacturing Indonesia (OMI). OMI, based in Indonesia, is an affiliated company of Malaysia-based Teck See Plastic Sdn. In March 2007, the Company established a joint venture with Teck See Plastic in Thailand. Upon completion of the capital increment, the trade name of OMI will be changed to P.T. Kasai Teck See Indonesia. The new company is expected to become a central manufacturing base in the ASEAN market for the Company, coupled with another facility in Thailand, to supply automotive interior parts such as door panels to Japanese carmakers located in Indonesia and will also serve as a hub for exporting component parts to be distributed in Japan and other Asian nations. (From a press release on Jul 15, 2008)


Business Restructuring
-In Dec. 2008, the Company announced that it will consolidate its two wholly owned subsidiaries making automotive interior parts in Gunma Prefecture. The integration, which will take place in April, 2009. The two companies are KPK Co., Ltd. (Meiwa-cho) and Mikuniseisakusyo Co., Ltd. (Ota City). KPK will absorb Mikuniseisakusyo and adopt a new name, Gunma Kasai Co., Ltd. Mikuniseisakusyo will be dissolved after the amalgamation procedure is completed. (From an article in the Nikkan Jidosha Shimbun on Dec. 16, 2008)

-In Oct. 2008, the Company announced its plan to reorganize manufacturing bases in South Kanto Area. Kasai Kogyo has decided to transfer the automotive interior parts operation at Ayase Plant of APM Co., Ltd., its subsidiary, to the Company's Samukawa Division. Thus, the group's automotive interior parts production capabilities in South Kanto, which have been carried out by the locations in Samukawa and Ayase, will be consolidated into the site in Samukawa. (From a press release on Oct 1, 2008)


Outlook for FY2009
Contracts

Automotive parts for the Honda Freed in Indonesia
-Start of Production: July 5, 2009
-Planned production volume: 2,000 units/month
-Parts being supplied: door trims (front/slide), tail gates, etc.

Automotive parts for the VW Passat
-Scheduled start of Production: January 2011
-Delivery to: VW's new Chattanooga Plant in the U.S.
-Planned production volume: 160,000 units/year
-Sales volume: approximately 15 billion yen over 5 years
-Parts being supplied: door trims (front/rear), roofs, front pillars, etc.
-Production facility: M-TEK Tennessee Plant

Sales Forecast by Region (on a Consolidated Basis) (in millions of JPY)
  FY2008 FY2009 (forecast)
Japan 57,208 48,919
North America 43,392 30,456
Asia 6,599 5,637
Europe 15,251 6,488
Total 122,452 91,500

Sales Share by Major Customer (%)
  FY2008 FY2009 (forecast)
Nissan group 60 61
Honda group 25 22
Toyota group 13 14
Others 2 3

R&D

R&D Expenditure (in millions of JPY)
  FY2008 FY2007 FY2006
Overall 655 521 544

-R&D activities are implemented mainly by Development Division

R&D Activities
1. Reducing weight of products
The Company developed a new production process, called Kasai Synchro Press (KSP), that reduces weight and thereby contributes to reducing CO2 emissions and fuel consumption.  The Company presented this as a solution for producing door trims used on mass-produced vehicles and started to supply the products to its customers. The KSP enabled the Company to reduce the weight of door trims by about 40% compared to door trims with the equivalent shape produced by a conventional process. Also, the Company developed a technology by applying its injection molding process, Kasai Press Molding (KPM) , that does not need any coating in the foam molding for reducing product weight and also ensures good external appearance quality. The Company used the technology in manufacturing doors and luggage trims of commercial vehicles and started to supply the products to its customers. With the foam molding process, the Company succeeded in reducing weight of the products by about 15%.

2. Safety
-The Company successfully created injection molded parts that are capable of absorbing energy, thus contributing to safety inside vehicles. These parts, which are characterized by their unique design structure, are being used in mass-produced vehicles. The accuracy of the Company's technology to analyze lateral collisions has reached the stage to where it can be put to practical use. This technology, which uses CAE (computer simulation),  was supported by validations conducted on bench tests.

3. Global environmental protection
-The Company is replacing glue and cleaning agents that contain VOC (Volatile Organic Compounds). The Company instead will use standard and water-based adhesives, in addition to materials, that are free of VOCs. As to the use of vinyl chloride materials, the Company is switching over to olefin-based thermoplastic elastomer (TPO) and urethane based thermoplastic elastomer (TPU).

4. Comfortable interior space
-The Company introduced CAE in its development activities to create cabin-interior products that improve anti-noise/soundproofing performance. These products offer a high degree of flexibility in their shape and come in a large selection of materials. They also are high precision, high quality products.  The Company is also making sales presentations of products that offer a high level of customer convenience, which were developed and planned based on benchmarking activities.

5. Quality
-The Company developed an applied technology that better stabilizes the final appearance of exterior surfaces of plastic molded products, thus reducing the number of defective products created while being manufactured.

6. Creating added values
-The Company is in the process of developing designing, coloring, and decorating technology for decorative components such as door-waist embellishments.

Investment Activities

Investment Expenditure (in millions of JPY)
  FY2008 FY2007 FY2006
Overall 6,708 8,640 13,011

-Investments were made in die production facilities in response to vehicle model changes.

Investment by Business Unit (in millions of JPY)
Locations  
Japan
Kasai 3,342
Mikuni Seisakusho Co., Ltd. 537
KPK Co., Ltd. 315
Kasai-Tec Co., Ltd. 204
Outside Japan
M-TEK Inc.(USA) 1,142
Guangzhou Kasai Automotive Interior Trim Parts Co.,Ltd.(China) 692
R-TEK Ltd.(UK) 164
Kasai Mexicana S.A. de C. V.(Mexico) 108
Kasai Teck See Co.,Ltd.(Thailand) 68


New Facilities(As of Mar. 2009)
Company name
Site name
Location Type of facility Planned investment
(million JPY)
Start Planned completion
Head Office Kanagawa Pref., Japan Quality measurement instruments, inspection tools 5,528 2009.04 2010.03
Samukawa Division Kanagawa Pref., Japan Facilities to assemble automotive interior parts, tools, and other items 134 2009.04 2010.03
Yorii Division Saitama Pref., Japan Facilities to assemble automotive interior parts, tools, and other items 15 2009.04 2010.03
Kyushu Division Ohita Pref., Japan Facilities to assemble automotive interior parts, tools, and other items 641 2009.04 2010.03
Mie Kasai Co., Ltd.
Head Plant
Mie Pref., Japan Facilities to assemble automotive interior parts, tools, and other items 43 2009.04 2010.03
Mie Kasai Co., Ltd.
Shiga Plant
Shiga Pref., Japan Facilities to assemble automotive interior parts, tools, and other items 12 2009.04 2010.03
Gunma Kasai Co.,Ltd.
Tatebayashi Plant
Gunma Pref.,
Japan
Facilities to assemble automotive interior parts, tools, and other items 7 2009.04 2010.03
Gunma Kasai Co.,Ltd.
Ota Plant
Gunma Pref.,
Japan
Facilities to assemble automotive interior parts, tools, and other items 2 2009.04 2010.03
Iwatekasai Iwate Pref., Japan Facilities to assemble automotive interior parts, tools, and other items 1 2009.04 2010.03
Kasai-Tec Co., Ltd. Shizuoka Pref., Japan Facilities to produce dies for automotive interior parts, tools, and other items 8 2009.04 2010.03
M-TEK Inc. Tennessee, USA Facilities to assemble automotive interior parts, tools, and other items 933 2009.04 2010.03
R-TEK Ltd. Tyne and Wear, UK Facilities to assemble automotive interior parts, tools, and other items 716 2009.04 2010.03
Kasai Mexicana S.A. de C. V. Guanajuato, Mexico Facilities to assemble automotive interior parts, tools, and other items 679 2009.04 2010.03
Guangzhou Kasai Automotive Interior Trim Parts Co., Ltd.
Guangzhou, China Facilities to assemble automotive interior parts, tools, and other items 242 2009.4 2010.3
Kasai Teck See Co.,Ltd.
Ayuttaya,
Thailand
Facilities to assemble automotive interior parts, tools, and other items 918 2009.4 2010.3