TOYOTA BOSHOKU CORPORATION Business Report FY2006
Business Highlights
| (in millions of JPY) | Mar. 2007 | Mar. 2006 | Rate of Change | Factors | 
| Overall | ||||
| Sales | 1,082,755 | 877,596 | 23.4% | Sales improved year-on-year, thanks to increased production of seats and door trims. | 
| Operating income | 52,143 | 37,838 | 37.8% | Despite fluctuating product prices and higher labor costs, both ordinary income and net income rose from what it was last year, as a result of increased production volume and sales. The Company's group-wide efforts to streamline operations also contributed to the rise. | 
| Current net income | 30,105 | 21,187 | 42.1% | - | 
| Automotive component business | ||||
| Sales | 1,078,714 | 873,954 | 23.4% | Sales at the automotive business rose from what they'd been the previous year as the Company increased production of interior parts (seats and trims) and air filters. | 
Business Performance by Geographic 
              Region 
Japan
              - Domestic sales were 655,486, million yen. The figure was 20.6 
              percent (or 111,952 million yen greater) than that of the previous 
              year, thanks to new models launches such as the Lexus and Corolla 
              by Toyota. 
North, Central, and South America 
              - Sales in the region climbed slightly by 2.2 percent or 5,051 million 
              yen year-on-year, to 230,248 million yen. The launch of full commercial 
              business activities to support GM in Mexico contributed to the rise. 
               
Asia 
              - Sales in Asia totaled 145,994 million yen, a rise of 89.0 percent 
              or 68,731 million yen compared to what it was last year. Some of 
              the major factors to the increase were favorable sales of the Toyota 
              Crown and Mark X released in Tianjin, China, as well as increased 
              production volume of the IMV series in ASEAN countries.  
Other regions
- Total sales in other regions were 51,026 million yen, up 61.5 
              percent or 19,423 million yuan year-on-year, supported by sales 
              of the Toyota Camry that was newly released in Australia. 
New Contracts
              - The Company won new contracts to supply rear seat relaxation systems 
              to the LS series of Corolla and Lexus models, Toyota's flagship 
              models to be marketed globally. The ergonomic rear seat system provides 
              a higher level of seating comfort in the LS models, the production 
              of which started recently. 
New Business Structure
              The Company has implemented the following two systems to enhance its management structure:
              - The Headquarters System: the Company introduced this new management 
              system to clarify business objectives and strategies and integrate 
              operations of each business sector.
              - Global Management System: the Company will control its four-region 
              organizational structure in a cross sectional manner according to 
              function.
              - In June 2006, the Company announced that it would undertake an organizational reform including introduction of "the headquarters 
              system," effective immediately. The company will also implement 
              a system to manage its corporate operations including those at overseas 
              production sites on a cross-sectional regional basis. The purposes 
              of introduction of the head office system are to clarify responsibilities 
              and authorities of each function, and also to consolidate operations 
              of interior systems, filters, powertrains and exterior fabrics. 
              Newly established headquarters include "Promotion of organizational 
              competence," "Profitability improvement," "Overseas 
              operations," "Quality improvement," and "Technology 
              development" to engage in development and designing of the 
              entire cabin. Under the new headquarters of "Production and 
              production engineering," three centers of "Production 
              engineering," "Production management," and "Manufacturing" 
              are established to take responsibility for all operations regarding 
              production for all product lines. (From an article in the Nikkan 
              Jidosha Shimbun on Jun. 23, 2006) 
Integration of overseas subsidiaries
              - In June 2006, the Company announced its plan to integrate its 
              subsidiaries in North America and Thailand. It will integrate three 
              of its North American units--"Araco America" (ARA), responsible 
              for research and development of interior components, "Takanichi-USA," 
              in charge of development and research of interior components and 
              marketing of door rims, and "Toyodabo America," which 
              markets automotive components--into "Toyota Boshoku America" 
              (TBA) on July 1 with ARA as a surviving company, with an aim at 
              producing approximately 5.9 billion yen in sales for fiscal 2005 
              with a workforce of 63. As for its Thai subsidiaries, Toyota Boshoku 
              will put together "Toyodabo Asia" (TBAS)--in chare of 
              marketing of filters as well as development of interior systems--and 
              "TNAT (Thailand)"--a system supplier of seats and other 
              interior components--as "Toyota Boshoku Asia" on July 
              1 with TBAS as a surviving company, and intends to earn around 7.8 
              billion baht in fiscal 2005 with 57 personnel (as of the end of 
              fiscal 2005).(From an article in the Nikkan Jidosha Shimbun on Jun. 
              28, 2006)
              Domestic Business
Improving Production and Supply Structure
              - Toyota Boshoku Kyushu Corporation will expand its Miyata plant 
              to enhance production capacity for door trims and air cleaners for 
              automobiles. This expansion is intended to support increased production 
              volume at Toyota Motor Kyushu.  
              - In September 2006, the Company announced it will establish a new 
              automotive parts manufacturing company in Koka city, Shiga prefecture, 
              to supply exclusively to Daihatsu Motor Co., Ltd. It will start 
              producing automotive filter and powertrain components, interior 
              components and exterior components in August 2007.  
              >>See Investment for more details
Overseas Business
<China>
              - By fiscal 2010, the Company aims to increase sales in China to 
              150 billion yen, which is 150 percent greater than estimated sales 
              for 2007. 
              - In July 2007, the Company and Denso Corporation jointly established 
              Toyota Boshoku Foshan Co., Ltd. (TBFC) to manufacture oil filters 
              for China and other Asian markets. TBFC expects to generate sales 
              of about 100 million yuan (approxiately 1.5 billion yen) in 2007 
              based on its plan to start manufacturing products also for the European 
              market in 2007. 
              <France>
              - Boshoku France S.A.S. (TBF) became operational in Onnaing, France 
              in May 2006. The new facility will initially focus on producing 
              replacement bumpers for the Corolla, Yaris, and Avensis assembled 
              in Europe. 
              <South Africa>
              - Toyota Boshoku South Africa (Pty) Ltd. (TBSA) started production 
              in April 2006; it targets sales of 10.4 billion yen in fiscal 2007. 
              <Canada>
              - In July 2006, the Company announced that it will establish a subsidiary 
              to manufacture car interior parts in Canada. The Group's first wholly 
              owned seat producing company in North America will start operations 
              in 2008 to supply seats and trims for automakers mainly in North 
              America.
              <Russia>
              - In April 2006, the Company and Toyota Tsusho Corporation announced 
              that they will establish a joint venture company to produce seats 
              in Russia. This is the first project in Russia undertaken by auto 
              parts suppliers in the Toyota Group. The new company, Toyota Boshoku 
              (Russia), will be established on the site of Toyota Motor Manufacturing 
              Russia (TMMR) located in St.Petersburg. 
 
>>See Capital Investment for more 
              details
Challenges for the future
 (1) To create more spacious cabin interiors:
 (2) To manufacture and supply the world's best automotive filters: 
              
              The Company will strengthen its oil filter business by increasing 
              the production volume of filters by 70% to more than 100 million 
              filters a year worldwide by 2010. It will achieve this by expanding 
              its current plants and building new ones in China, Thailand and 
              other Asian countries. At the same time, Toyota Boshoku will accelerate 
              its R&D activities on oil filters for both OEM use and the aftermarket, 
              making filters which better meet  the requirements of the two 
              different usages, i.e., OEM and aftermarket, through creating filters 
              that offer greater efficiency and other new features. These initiatives 
              are expected to help the Company increase sales to gain a 10% share 
              of the global market. (From an article in the Nikkan Jidosha Shimbun 
              on Apr. 14, 2005)
(3) To establish a global supply network
R&D
R&D Expenditure
              R&D costs totaled 26,404 million yen, all of which were for 
              automotive business.
R&D Structure 
              - The Company will strengthen the R&D organization of advanced 
              technologies. In place of current system staffing more employees 
              for product development, the company will shift the staff for advanced 
              technologies. In consideration of increasing needs for sophisticated 
              features regarding health or comfort for the car interior, the company 
              will concentrate on R&D of advanced technology aiming to enhance 
              its competitiveness. Currently 85% of development staff are put 
              into product development, with the remaining 15% are in advanced 
              development. When adding development staff, the company will make 
              the number equal for product development and advanced development 
              to focus on the latter. (From a story in the Nikkan Jidosha Shimbun 
              on Jul. 3, 2006)
<Interior system supplier business> 
              In response to Toyota's model changeovers, the Company launched 
              production of components for the new Lexus LS, the main Lexus models 
              being sold in Japan. It also started manufacturing components for 
              the Camry marketed globally and the IMV series sold in Africa.
Lexus LS
              For the Lexus LS, the Company developed and supplies rear seats 
              with relaxation systems; and electric sunshades for rear side windows. 
              It also provides its new electronics technology, supplying large 
              LED blade illumination systems. 
              - The Company is developing door trims by use of plant-based bioplastic 
              materials. The Company has already finished production of a prototype 
              on the basis of "Kenaf Polylactides, "which are materials 
              combining annual kenaf grasses with lactic acid plastic produced 
              by Toyota. The Kenaf Polylactides were developed jointly by Toyota 
              and Toray. Although they are more costly than oil based plastics, 
              they are lighter by almost one-third. (From an article in the Nikkan 
              Jidosha Shimbun on Jun. 24, 2006)
<Filtration & Powertrain Components>
- In addition to working on enhancing product performances and 
              reducing costs, the Company focuses its development activities on 
              making modular and system products, enhancing environmental sustainability, 
              and improving riding comfort. 
              - The Company developed and supplies compact and high performance 
              air cleaning filters that incorporate valve and chemical fiber technologies 
              for the Lexus LS. The new filter with lower air-flow resistance 
              and improved dust filtering technology contributes to achieving 
              high engine power and reliability. 
              - The Company developed low cost and light-weight oil filters by 
              using plastic caps instead of aluminum caps. The new filters achieves 
              the same level of filtering technology as existing products, while 
              providing oil leak prevention function with a safety structure. 
              The oil filter is used in the Lexus LS.
Investment Activities
In 2006, the Company invested 47,550 million yen in total for the construction of plants, expansion of manufacturing facilities, as well as development of new products.
- Total investments in the interior component division amounted to 36,840 million yen. This included spending to prepare production lines to manufacture new seats and door trims, and to increase production in China; and North, Central and South America.
- Investment in the Filter and Powertrain product division reached 6,068 million yen. Investments were focused on preparing production lines to manufacture new air filters and oil filters.
Japan
- In September 2006, the Company announced that it will expand Miyata plant of its subsidiary Toyota Boshoku Kyushu Corporation to enhance production capacity for door trims and air cleaners for automobiles with an investment of about 1.35 billion yen. Toyota Boshoku Kyushu is a manufacturer and supplier of seats and door trims of the Harrier, Kluger and Lexus IS for Toyota Motor Kyushu, Inc. This expansion is to cope with the stepped-up production of Toyota Motor Kyushu. The construction will complete in March 2007 to produce door trims, deck side trims and air cleaners. (From an article in the Nikkan Jidosha Shimbun on Sep.27, 2006)
- In September 2006, the Company announced the establishment of a new automotive parts manufacturing company in Koka city, Shiga prefecture, to supply only to Daihatsu Motor Co., Ltd. It will start producing automotive filter and powertrain components, interior components and exterior components in August 2007 to deliver to Shiga Plant, Kyoto Plant, Ikeda Plant and Nishinomiya Parts Center of Daihatsu. The new company, Toyota Boshoku Shiga Corp., will be capitalized at 240 million yen, fully invested by Toyota Boshoku Corp. as its first "Daihatsu" exclusive plant. Etsuro Hori, General Manager of Toyota Boshoku, will be the president. 200 employees are expected to be hired to manufacture mainly plastic molding products such as plastic intake manifolds, air cleaners, floor carpets, door trims and replacement bumpers.(From an article in the Nikkan Jidosha Shimbun on Sep. 2, 2006)
- In January 2007, the Company and and Denso Corporation announced that they held an opening ceremony of Toyota Boshoku Foshan Co., Ltd. (TBFC). TBFC is a joint venture between Toyota Boshoku and Denso. TBFC started its production of oil filters for China and other Asian markets in July 2006 and it plans to expand its production for the European market in 2007. TBFC is planning to achieve about 100 million yuan (about 1.5 billion yen) in 2007. (From an article in the Nikkan Jidosha Shimbun on Jan.24, 2007)
Overseas
              <China>
              - The Company plans to expand by FY 2010 sales in China to 150 billion 
              yen, approx. 2.5 times as large as the FY 2006 sales forecast. As 
              large increase is expected of Toyota vehicle production in China, 
              the company plans to expand sales of interior materials for these 
              locally produced vehicles. Responding to Toyota Motor Corp.'s globalization, 
              the company has been enhancing its production operations overseas. 
              It will work on expanding business in China while enhancing development 
              and production operations there to develop its China business to 
              the third largest scale after Japan and the U.S.A. (From an article 
              in the Nikkan Jidosha Shimbun on Nov.24, 2006)
              - In January 2007, the Company, Aisin Seiki Co., Ltd., and Denso 
              Corporation, three companies in the Toyota group, announced that 
              they held a joint opening ceremony of Aisin Seiki Foshan Body Parts 
              Co., Ltd. (ASFB) and Toyota Boshoku Foshan Co., Ltd. (TBFC). ASFB 
              is a subsidiary of Aisin Seiki and TBFC is a joint venture between 
              Toyota Boshoku and Denso. ASFB has been producing electric sunroofs 
              and motor housings for power seats from May 2006. TBFC started its 
              production of oil filters for China and other Asian markets in July 
              2006 and it plans to expand its production for the European market 
              in 2007. ASFB expects annual sales of approx. 377 million yuan (about 
              5.67 billion yen) while TBFC is planning to achieve about 100 million 
              yuan (about 1.5 billion yen) in 2007. (From an article in the Nikkan 
              Jidosha Shimbun on Jan.24, 2007)
              <France>
              - In October 2006, the Company announced that it held an opening 
              ceremony of Toyota Boshoku France S.A.S. (TBF) - its new manufacturing 
              facility for automotive bumpers. Located in Onnaing City, France, 
              TBF has launched production of aftermarket bumpers for Toyota vehicles 
              with an annual production capacity of 250,000 units. The new subsidiary 
              was established in January 2005, with 100% of the capital provided 
              by Toyota Boshoku Corporation. The bumper plant, worth 8 million 
              euros in investment, started operating in May 2006 and will focus 
              on producing replacement bumpers for the Corolla, Yaris, and Avensis 
              made in Europe for the time being. (From an article in the Nikkan 
              Jidosha Shimbun on Oct.11, 2006)
              <South Africa>
              - In October 2006, the Company and Toyota Tsusho Corporation announced 
              on October 4 that they held an opening ceremony of Toyota Boshoku 
              South Africa (Pty) Ltd. (TBSA)-their first manufacturing facility 
              in South Africa. Attended by government officials and top executives 
              of both companies, the ceremony took place at the new plant site 
              equipped with leading edge manufacturing equipment for automotive 
              interior parts. TBSA was established in KwaZulu-Natal, South Africa 
              in July 2005 with a total investment of approximately 4.3 billion 
              yen. Production of automotive interior parts such as seats and door 
              trims started in April 2006. The new company targets sales of 10.4 
              billion yen in fiscal 2007. (From an article in the Nikkan Jidosha 
              Shimbun on Oct.5, 2006)
              <Canada> 
              - In July 2006, the Company announced that it would establish a 
              production company of car interior parts, Toyota Boshoku Canada 
              Inc. (TBCA), which is its first wholly owned seat producing company 
              in North America. TBCA will start operations in 2008 to supply seats 
              and trims for automakers mainly in North America, expecting that 
              2009 annual sales will be around 15 billion yen. The new subsidiary 
              will be established in Woodstock, Ontario, Canada to respond to 
              the needs of Japanese carmakers including Toyota to procure parts 
              locally, and also with the aim of enhancing competitiveness in the 
              global market. TBCA will be positioned as a critical site in North 
              American business of Toyota Boshoku, as seen in a plan to supply 
              interior parts for RAV4 to be produced by Toyota Motor Manufacturing 
              Canada Inc. (TMMC) that will begin operations in 2008.(From a story 
              in the Nikkan Jidosha Shimbun on Jul. 11, 2006)
<Russia>
              - In April 2006, the Company announced on April 10 to establish 
              a subsidiary in Russia to produce seats for vehicles in joint venture 
              with Toyota Tsusho Corporation. This is the first project in Russia 
              by auto parts suppliers in the Toyota Group, and the 56th overseas 
              facilities of Toyota Boshoku. A new company "Toyota Boshoku 
              (Russia)" will be established in the site of "Toyota Motor 
              Manufacturing Russia (TMMR) "located in St.Petersburg. In time 
              with production of Toyota Camrys at TMMR starting in December 2007, 
              Toyota Boshoku (Russia) will produce 20,000 sets of seats for the 
              model per year. It will start the operation with production by complete 
              knockdown system using most of components including mechanical parts 
              of seat slides and seat rails as well as seat fabrics imported from 
              Japan. Approximately 330 million yen will be invested in transfer 
              and introductionof machinery and equipment used mainly for cutting 
              urethane foam materials and fabrics. The number of employees at 
              the startup will be about 90.(From a story in the Nikkan Jidosha 
              Shimbun on Apr. 11, 2006)
| New Facilities | ( in millions of JPY ) | 
| Name | Location | Type of facility | Planned investing amount | Start | Finish | 
| Sanage Plant | Aichi, Japan | Manufacture of new type of seat and door trims; maintenance and renewal of existing facilities | 7,753 | 2007.04 | 2008.03 | 
| Kariya Plant | Aichi, Japan | Manufacture of new type of air filters | 4,339 | 2007.04 | 2008.03 | 
| Shiga Plant | Shiga, Japan | Construction of a new facility to manufacture bumpers, cylinder head covers, etc.; manufacture of new products | 3,280 | 2007.04 | 2008.03 | 
| Oguchi Plant | Aichi, Japan | Manufacture of new type of molded ceilings, fender liners; maintenance and renewal of existing facilities | 2,149 | 2007.04 | 2008.03 | 
| Dobashi Plant | Aichi, Japan | Research and development of electric components; manufacture of new products | 2,017 | 2007.04 | 2008.03 | 
| Fuzioka Plant | Aichi, Japan | Manufacture of new type of door trims; maintenance and renewal of existing facilities | 1,662 | 2007.04 | 2008.03 | 
| Takaoka Plant | Aichi, Japan | Manufacture of new type of seat and door trims; maintenance and renewal of existing facilities | 4,671 | 2007.04 | 2008.03 | 
| Toyohashi-kita Plant | Aichi, Japan | Manufacture of new type of seats ; maintenance and renewal of existing facilities | 1,028 | 2007.04 | 2008.03 | 
| Toyota Boshoku Canada Corp | Ontario, Canada | Manufacture of new type of seat and door trims | 6,454 | 2007.04 | 2008.03 | 
| Trim Masters Inc.Grope | Kentucky, USA | Facilities for new type of seat and door trims and frames | 2,901 | 2007.04 | 2008.03 | 
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