The global market for automotive interiors - sample copy

Transcription

All content copyright © 2002 Aroq Limited
The global market
for automotive interiors - sample copy
Published May 2002
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The global market for automotive interiors
Chapter 2 Interiors market overview
Seat assembly market positions
It is estimated that Lear and Johnson Controls lead the $xx billion global
market for complete seat assemblies. Johnson Controls, however, is likely to
take over the lead on the world stage following its recent acquisition of Ikeda
Bussan.
Figure 1 World automotive seating manufacturers’ market shares
(% volume)
CHART
Sources: just-auto.com/industry estimates
Faurecia leads the $x.x billion market for complete seating in Western Europe,
closely followed by Johnson Controls and Lear.
7
Figure 2 Western Europe shares of the automotive seating market
(% volume)
CHART REMOVED - SAMPLE COPY
In addition to the big three seat makers, there are a number of other
companies supplying seat parts. Like the big three, they have also formed
alliances and merged their operations.
Most recently, Schukra, the lumbar support specialist has merged with the
Leggett & Platt (L&P) Automotive Group, a major supplier of seat comfort
systems and (seat) suspension components to the automotive industry.
Schukra plans to continue as an individual entity, and as part of L&P, will offer
the important seat comfort elements. Schukra is developing an intelligent
lumbar system that can be used in seat bolster systems.
8
Volvo
Volkswagen
Skoda
Seat
MG Rover
Renault
PSA Peugeot Citroën
Porsche
MCC Smart
Jaguar
GM/ Opel Vauxhall
Ford
Fiat
DaimlerChrysler
BMW
Audi
Table 1 Europe: Suppliers of vehicle seats to European vehicle makers, 2002
Brose
CESA
ContiTech
Faurecia
Johnson Controls
DATA REMOVED – SAMPLE COPY
Keiper
Lear
Leggett & Platt
Magna
Rectical
Ricaro
Tower
Source: Auto Business
In North America, the main seat manufacturers are Lear, Johnson Controls,
Magna International (Intier Automotive) and Visteon. They dominate over xx%
of the $x.x billion annual market for complete seating. Other manufacturers
include TS Tech (owned by Tokyo Seat Co), Vintec (a joint venture between
Johnson Controls and Ikeda Bussan), General Seating (a joint venture
between Lear Corp and NHK Spring) and Trim Masters.
Araco and Johnson Controls, which are partners in Trim Masters, plan to set
up a new joint venture in the US by autumn 20xx, to manufacture metal seat
parts such as recliners. With almost all of Trim Masters' business being with
Toyota, Araco wants the new venture to use Johnson Controls as a channel in
which to expand business and supply seat assemblies to other vehicle makers.
The new plant is likely to start production in the autumn of 20xx, and will also
supply to Trim Masters and Johnson Controls.
Lear and NHK Spring, meanwhile, jointly operate the General Seating of
America plant and the General Seating of Canada plant which makes seats for
Subaru-Isuzu Automotive Inc. and CAMI Automotive Inc, respectively.
9
Figure 3 North America: shares of the automotive seating market
(% volume)
CHART REMOVED - SAMPLE COPY
In Japan, Tachi-S is said to lead the seat market, followed by Araco Corp
(supplier to Toyota amongst others), Ikeda Bussan (supplier to Nissan),
Takashimaya Nippatsu Kogyo Co Ltd (supplier to Toyota), Tokyo Seat Co Ltd,
Nanba Press Works Co Ltd (supplier to Mitsubishi), Fuji Seat Co Ltd, and
Delta Kogyo Co Ltd (supplier to Mazda).
In 20xx, Araco bought a xx% equity stake in the Japanese seat maker Cowerk.
Araco aims to increase its productivity as well as speed up the process of
development to production. Cowerk supplies xx% of the seats for the vehicles
assembled at Toyota Auto Body.
Also in 20xx, Takashimaya Nippatsu Kogyo Co Ltd, a subsidiary of NHK
Spring, set up a joint venture company in Thailand along with its parent
company for developing seat technologies. The new company, known as
TNAT, is capitalised at BAHT40 million. Takashimaya Nippatsu holds a xx%
stake and NHK Spring holds a xx% stake with NHK's Thai subsidiary providing
xx%.
The joint venture develops seat technologies for Toyota's strategic car, which
will begin production in the Southeast Asian region in 20xx. Takashimaya
Nippatsu believes that localising R&D will help to reduce development costs
and time. TNAT will initially work with Takashimaya Nippatsu's domestic
technical centre to develop standard designs for seats and studies on
localising parts sourcing. Takashimaya Nippatsu Kogyo supplies seats and
door panels to Toyota Motor.
In Vietnam, Takashimaya Nippatsu Kogyo is planning to double its production
of seat covers at Takanichi Vietnam Co, Ltd (TVC) to supply to manufacturing
operations in the US. As a result, Takashimaya will invest $2.9 million and
double its land area to xx,000 m² and factory floor space to x,000 m². The
company will also take on another xx workers, raising total employment at the
plant to xxx people. The company has opted to produce seat covers at TVC,
as labour costs are lower in Vietnam.
10
Seat cover production at TVC is likely to begin in the second half of 20xx. TVC
will supply seat covers to the new Takanichi Lear joint venture in the US, Total
Interior Systems-America (TISA) established in 20xx in Indiana, noted earlier.
It is expected to begin functioning in 20xx. TVC aims to provide nearly xx,000
covers to TISA.
Door trim panel market positions
According to Lear, door panels consist of several component parts that are
attached to a substrate by various methods. Specific components include vinyl
or cloth-covered appliqués, armrests, radio speaker grilles, map pocket
compartments, carpet and sound-reducing insulation. In addition, door panels
often incorporate electrical distribution systems and electrical/electronic
products, including switches and wire harnesses for the control of power seats,
windows, mirrors and door locks.
In Europe, Faurecia claim to lead the $x.x billion door trim panel market with a
xx% share. Faurecia offers door panels, door modules and door systems to
the world’s major vehicle makers. Its offering includes a complete door system,
integrating all the door’s component parts. Faurecia says it is aiming to
become a ‘full system supplier’ to the automotive industry for complete door
systems.
Johnson Controls ranks in second place in Europe, followed by Visteon,
Treves and Venture. Others include Lear, Intier, Findlay and Seeber.
Last year, plastic components maker Seeber posted sales of DMxxx million, all
of which was earned in the automotive sector. Its product range covers interior
trim components, instrument panels and consoles and engine components
such as activated charcoal filters, power steering and brake fluid reservoirs as
well as intake and charge-air pipes. Its major customers include Audi, BMW,
DaimlerChrysler, Ford, GM/Opel and other OEMs. The company recently set
up a 'Creative Centre' focusing on three main areas: prototype build, testing
and a customer sector providing a high level of customer confidentiality. There
is also a separate development area working on independent projects not
related to the company's core work
In North America, Lear leads the $x billion automotive door trim panel market
with a xx% share, followed by Visteon, Johnson Controls and Magna’s Intier
Automotive.
11
Error! Reference source not found.
Johnson Controls recently opened a new interior plant in Warren, Michigan to
manufacture door trim panels for DaimlerChrysler cars and trucks. The xxx,xxx
sq. ft. facility is unusual in that it also houses the operations of Becker Group,
whose employees manufacture the injection-moulded plastic door trim panels
and then pass them to Johnson employees for assembly and subsequent
delivery.
Johnson says the system has led to reduced costs, faster working and higher
quality. The new facility also makes door panels for the Jeep Cherokee, which
were previously made at its Michigan plant, but has since been closed down.
Johnson Controls actually bought out the US and European operations of
Becker Group in 19xx, but a year later, Charles Becker, the founder, bought
several plants back from them.
In Japan, local manufacturers dominate the market, led by Kasai Kogyo,
Takushimaya Nippatsu Kogyo (TNK), TS Tech and Araco. In a bid to reduce
its debt, Nissan Motor has sold a x.x% stake in its affiliate Kasai Kogyo Co to
Akebono Brake Industry Co on 1st March 20xx. By selling these stakes,
Nissan's stake in Kasai Kogyo has been reduced from xx.x% to x.x%, thereby
making Nagase & Co a major shareholder in Kasai Kogyo.
Kasai Kogyo intends to build a factory in Mississippi, US to supply parts to a
new plant of Nissan Motor Co. Construction of the ¥x billion facility should be
completed by September 20xx and become operational from June 20xx. The
new plant will make roof trim, door trim, carpets and other interior components.
The company expects to report sales of $xx million in the first year of operation
and $xx million in the second year.
Through a joint venture agreement, Lear is picking up new business with the
Japanese transplants located in the US. In November 20xx, Lear entered a
joint venture with TNK. The joint venture, Total Interior Systems-America
(TISA), already has a contract to supply Toyota Motor Manufacturing's Indiana
plant with seating systems for the Toyota Sienna multi-purpose vehicle. TISA
says it will locate a facility in Princeton, Indiana to allow it to make and deliver
seat systems on a Just-In-Time basis to the Toyota plant. Production will begin
in 20xx.
12
TNK is a supplier of seats and door panels to Toyota with 19xx sales of $xxx
million. From a global perspective it is a minor player, but its performance is
good nonetheless. The company employs xxxx people at eight assembly
plants in Japan, as well as at its operations in China, the Philippines, Thailand,
Turkey and Vietnam.
Headliners market positions
Grupo Antolin claims to lead the $xxx million West European automotive
market for headliners. During the 19xxs, Grupo Antolin expanded its
operations, entering Germany, the UK, France, Portugal, the US, Mexico,
Turkey, the Czech Republic, Slovakia, Brazil, Argentina, South Africa, India,
Thailand, Japan, South Korea and China. Antolin operates xx plants and xx
technical and commercial offices.
In second place is Johnson Controls, followed by Lear (with xx%), Tramico and
Findlay. In a bid to strengthen its position in the European interiors market,
Johnson Controls acquired two manufacturing facilities in Hanover, the
German-based automotive interior supplier Benecke-Kaliko AG in 19xx. The
transaction added new roof-reinforcing technologies that has since enabled
Johnson Controls to integrate premium components - including head
protection airbags - into headliner systems and interior pillar products.
The intention of the first headliners was simply to cover the sheet metal and
roof structure of a vehicle, contributing to interior aesthetics. For some time,
headliners were little more than that. Today, headliners are typically referred to
as overhead systems, featuring the headliner substrate itself, sun visors, grab
handles, coat hooks, overhead console, ducting vents and wiring. For a
convertible roof system, a top, mechanism or frame, motor, glass or plastic,
and boot need to be added. They are delivered fully assembled in-sequence to
the vehicle maker. The headliner itself consists of a substrate as well as a
finished interior layer made of a variety of fabrics and materials.
The total value of this market is gradually rising as more parts are added. The
ever-popular sports-utility vehicles and multi-purpose vehicles in North
America, Europe and Japan are helping to grow the market. A ‘fully loaded’
SUV headliner with multimedia applications, sun visors and a multitude of
electrical ducting can typically add up to about $xxx to the cost of a vehicle.
13
Volvo
Volkswagen
Skoda
Seat
MG Rover
Renault
PSA Peugeot - Citroën
Porsche
MCC Smart
Jaguar
GM/ Opel Vauxhall
Ford
Fiat
DaimlerChrysler
BMW
Audi
Table 2 Europe: Suppliers of vehicle headliners to European vehicle makers, 2002
Autoform
Autoliv
Collins & Aikman
Dexter
Empetek
Eurostyle
Faurecia
Fico
Findlay
Illbruck
Industriale Sud
Irausa
Johnson Controls
JRI Technologies
Lear
Philippine
Rieter
Sicar
Tramico
Tramico
Visteon
In the North American headliner market, worth some $xxx million, Johnson
Controls is in pole position, followed by Lear, Grupo Antolin, Interier
Automotive and M-Tek.
Kasai Kogyo, an interior components manufacturer for Nissan Motor Co is
planning expansion at M-TEK, its US subsidiary. The $xx million investment on
construction and facilities will lead to increased capacity, which will enable the
company to meet new orders for door trim for Honda's next Accord model,
ceiling for the Ford Mustang and interior parts for Ford-Mazda.
14
In Japan, Toyoda Boshoku is the largest supplier of vehicle headliners,
followed by local producers Howa Textile Industry, TS Tech and Sanwa
Kogyo.
Vehicle acoustics market positions
Lear estimates that the vehicle acoustics market is worth $x.x billion in North
America, $x.x billion in Western Europe and $x.x billion worldwide. Lear claims
a xx% share in North America, x% share in Western Europe and xx% share
worldwide.
Rieter Automotive Systems is also one of the world's leading suppliers of noise
control and thermal insulation systems in motor vehicles. Headquartered in
Winterthur, Switzerland, Rieter operates xx plants around the world employing
some x,xxx people. In 20xx, Rieter Automotive Systems acquired a majority
share in Italian vehicle engineering company I.D.E.A., which has major vehicle
makers amongst its clientele, including Fiat. The move allowed Rieter to gain
valuable designer and engineering experience from I.D.E.A., helping it towards
its plan of becoming a leading global acoustic integrator and full-service
supplier.
I.D.E.A. also benefits from access to Rieter's markets as well as its global
customers. I.D.E.A. was founded in 19xx by Franco Mantegazza and operates
six centres with an annual turnover of around €xx million and xxx workers.
In 20xx, Rieter entered into a joint venture with the Austrian carpet-producer
Durmont to develop high-end carpet products for European vehicle makers.
Durmont is an ideal partner for Rieter Automotive, as it is a leading producer of
high-end carpets for the European market. Through the alliance with Rieter
Automotive Systems, Durmont returns to the automotive carpet business. In
the mid-1990s the former owner of Durmont sold the automotive carpet
business to Magna, while the new majority owner, Anker group in Germany,
renewed concentration on this business.
Germany-based Illbruck Automotive is also one of the major suppliers of sound
proofing systems in Europe. Family-owned Illbruck was recently renamed
Carcoustics International GmbH. The renaming took place after a takeover by
Dutch company NIB Capital and the departure of the Illbruck group of
companies.
15
Over the next few years, Carcoustics is planning to grow by xx to xx% per
year. The company believes that this growth is already guaranteed as a result
of certain development projects that have already been negotiated.
Carcoustics specialises in vehicle acoustics products and expects future
opportunities in this area as noise regulations become stricter. The growth in
sales of diesel cars has also increased demand for vehicle acoustic products.
In 20xx, the company expects its turnover to increase from a current €xx
million to €xxx million. According to its main shareholder, NIB Capital, the
company could become the world market leader in acoustics products through
further acquisitions.
16
Volvo
Volkswagen
Skoda
Seat
MG Rover
Renault
PSA Peugeot - Citroën
Porsche
MCC Smart
Jaguar
GM/ Opel Vauxhall
Ford
Fiat
DaimlerChrysler
BMW
Audi
Table 3 Europe: Suppliers of vehicle sound proofing to European vehicle makers, 2002
AB Fiberduck
Ahlstrom
Borgers
British Vita
CA Greiner & Sohne
Collins & Aikman
CWW-Gerko
Dana
Dow Automotive
Faurecia
HBS Technologie
HP Chemie-Petzer
Illbruck
Inapal
Magna
Molan
Odenwald
Ovatex
Phoenix
Plasto Foamade
Reinz
Rieter
Rutgers
Saifer-Keller
Schaeffler
Sofanou
Solvay
Stankiewicz
TMG
Treves
Treves
17
In North America the joint venture Magee Rieter is Rieter Automotive's carpet
product source. Magee Rieter is a xx:xx joint venture between the automotive
carpet manufacturer Magee of Bloomsburg, Pennsylvania, and Rieter. Magee
Rieter Automotive Systems is a supplier of fabricated carpet and acoustical
systems to a number of vehicle makers, with GM being its largest customer.
In Japan, Hayashi Telempu leads the vehicle carpet market. Hayashi Telempu
recently entered into a joint venture with Faurecia to create a global supply
network to meet the demand of vehicle makers.
Hayashi Telempu was prompted to form the alliance as its largest customer,
Toyota Motor, is planning to set up a xx:xx joint venture with Peugeot to make
subcompact cars from 20xx. Both Hayashi Telempu and Faurecia will use
each other's sales networks and production facilities to produce various interior
parts such as carpets. As a result of the alliance, Hayashi Telempu will use
Faurecia's production unit to supply customers in Europe.
In late 20xx, Hayashi Telempu won its first order to supply interior parts to
Nissan Motor. It will supply floor carpet for Nissan's new Fairlady Z that will be
launched in 20xx. Hayashi will supply carpet for about x,xx units of the Fairlady
Z annually.
Vehicle carpet market positions
There are at least xx suppliers of vehicle carpets in Europe, led by Faurecia,
Magna (Intier Automotive) and Treves.
18
Volvo
Volkswagen
Skoda
Seat
MG Rover
Renault
Porsche
MCC Smart
Jaguar
GM/ Opel Vauxhall
Ford
Fiat
DaimlerChrysler
BMW
Audi
Table 4 Europe: Suppliers of vehicle carpets to European vehicle makers, 2002
Berco
Borgers
BOS
CA Greiner
Collins & Aikman
Copo
Dura
Emfisint
Era
Eurostyle
DATA REMOVED – SAMPLE ONLY
Faurecia
GIA
HP Chemie-Pelzer
In-house
Lear
Magna
Orsa
Phoenix
Radici
Rieter
Saifa
Sama
San Valeriano
Schaeffler
Silac
Stankiewicz
Treves
19
Error! Reference source not found.
In North America, Collins & Aikman claim to lead the North American - and
world - market for vehicle carpets, thanks to a string of significant new awards.
In 20xx, DaimlerChrysler took the decision to award Collins & Aikman with a
contract to supply floor mats and carpet for both the right- and left-hand drive
models of the 20xx Chrysler PT Cruiser vehicle built at DaimlerChrysler's Graz,
Austria facility. The floor mats and carpets are now being produced at Collins
& Aikman's European facilities located in Belgium and Austria.
Other suppliers of vehicle carpets in North America include Lear, Rieter and
Amtex Inc. Amtex is a joint venture between Lear and Nagoya. Amtex supplies
New United Motor Manufacturing Inc.(NUMMI) with floor carpeting, boot lining,
spare tyre covers, dashboard insulators and various other interior trim
products. NUMMI is the Fremont-based joint venture between Toyota and GM
that employs x,xxx people producing three vehicles - the Toyota Corolla
sedan, the Toyota Tacoma pick-up truck, and the Chevrolet Prizm sedan.
Instrument panel market positions
Following its acquisition of Sommer Allibert, the French group, Faurecia,
claims to lead the European instrument panel market, worth some $x.x billion
annually.
In second place is Visteon, thanks to its acquisition of Plastic Omnium's
vehicle interiors business for FFrx billion in 19xx. Plastic Omnium’s interior
components division designs and manufactures a range of instrument panels,
dashboards, centre consoles, door panels and interior trim.
The automotive interiors business of Plastic Omnium employs x,xx people at x
facilities in France, Spain, Italy and the UK. Plastic Omnium’s customers
include xxx. It operates an R&D Centre in Gondecourt, France and has
development alliances with Treves, France (through Tredndel), Kasai Kogyo
(through R-TEK, UK) and Risselberg, Belgium.
Johnson Controls and Intier Automotive also have a strong presence in the
European automotive instrument panel market.
20
In 20xx, Johnson Controls acquired the automotive business of French
company Sagem, which specialises in software and systems engineering
crucial to the design of a car's electrical and electronic systems architecture.
The €xxx million acquisition gives Johnson an important link in its plan to
supply fully integrated cockpit and interiors systems. The acquisition also gives
Johnson a new base in the European marketplace to sell its full range of
electronics, opening up new business with Peugeot and Renault, Sagem's two
largest customers.
21
Volvo
Volkswagen
Skoda
Seat
MG Rover
Renault
Jaguar
GM/ Opel Vauxhall
Ford
Fiat
DaimlerChrysler
BMW
Audi
Table 5 Europe: Suppliers of vehicle instrument panels to European vehicle makers, 2002
Alveo
Antolin
Becker
Bosch
Bourbon Fabi
Collins & Aikman
ContiTech
Delphi
Faurecia
Gedia
Inalfa
Johnson Controls
LDM
Lear
Magna
Magneti Marelli
Plastal-ZCP
Recticel
Rutgers
Siemens VDO
TMG Automovel
UK-NSI
Valeo
Venture
Visteon
22
Volvo
Volkswagen
Skoda
Seat
MG Rover
Renault
Porsche
MCC Smart
Jaguar
GM/ Opel Vauxhall
Ford
Fiat
DaimlerChrysler
BMW
Audi
Table 6 Europe: Suppliers of vehicle cockpits to European vehicle makers, 2002
Becker
Borg
Bosch
Delphi
Faurecia
In-house
Johnson Controls
Lear
Magna
Magneti Marelli
PCG
Seeber
Siemens VDO
TRW
Venture
Visteon
In North America, Visteon leads the vehicle instrument panel market,
estimated to be worth $x.x billion annually, followed by Textron (now Collins &
Aikman), Delphi and Toyota with double-digit shares. There is then a long tail
of other suppliers, including Kantus, Honda, Lear (with x%), Intertec (Intertec
Systems is a joint venture between Inoac Corporation of Japan and Johnson
Controls) and Faurecia.
In Japan, Toyota, Kansai, Suzuki and Mitsubishi Belt lead the instrument panel
market. Mitsubishi Belt, a manufacturer of automotive belts and plastic
products, has a joint venture with Visteon to develop, manufacture and market
plastic components for cockpit modules.
23
Merger and acquisition activity
For many interior suppliers, mergers and acquisitions offer the quickest route
to attaining either global reach or systems capability. In this regard, the North
American component companies have been most active. Some notable deals
struck over the last two years include:
Collins & Aikman Corp. will become one of the world's largest makers of
automotive interior components with its recent $x.x billion purchase of Textron
Inc’s automotive trim business (TAC-Trim). The deal will nearly double Collins
& Aikman's annual sales to $x.x billion, lift employment to more than xx,xxx at
xxx locations in Europe and North and South America, and boost the firm's
range of polyurethane-based products.
Collins & Aikman had sales of about $x billion in 20xx and claims to be the
global leader in automotive floor and acoustic systems. TAC-Trim had sales of
$x.xx billion in 20xx and says it is one of the world's leading suppliers of fully
integrated cockpits, and a major manufacturer of automotive parts, including
instrument panels, interior trim and exterior components.
In contrast to Collins & Aikman, TAC-Trim's PU capabilities are focused on
foam-based instrument and door panels and headliners. Reaction injection
moulding is another key technology for TAC-Trim.
Collins & Aikman has several plants with significant PU operations focusing on
carpet insulation and noise, vibration and hardness control systems. Collins &
Aikman also has a Spray Urethane Barrier technology which can be moulded
to meet complex design requirements.
Following Renault’s purchase of a xx.x% stake in Nissan in 19xx, Nissan set
about changing its equity relationships with its suppliers by selling its shares in
seating parts makers Tachi-S and Fuji Kiko. The carmaker also moved to
disengage itself from another seating manufacturer, Ikeda Busan, in which
Nissan held a xx% stake.
In August 19xx, Tachi-S and Fuji Kiko reached an agreement with Nissan
Motor, whereby Tachi-S acquired the xx.x% equity stake in Fuji Kiko that was
then held by Nissan Motor, and Fuji Kiko acquired more than half of the xx%
equity stake in Tachi-S that Nissan Motor owned. Tachi-S then bought back
and cancelled the remaining outstanding Tachi-S shares held by Nissan Motor.
24
Fuji Koko Co Ltd manufactures structural components for car seats with
annual sales of around ¥xx billion.
In July 20xx, Johnson Controls announced its intention to acquire the
Japanese seat maker Ikeda Bussan Co., a Nissan Motor Co. affiliate,
consolidating its leading position in seats and interiors. Nissan owned xx% of
Ikeda Bussan and NHK Spring Co. held xx% with the remainder widely held.
Johnson Controls and Ikeda Bussan have joint ventures making seats for
Nissan in the US and Europe dating back to 19xx, but have little other overlap.
Nissan accounts for more than xx% of Ikeda Bussan's revenues.
Johnson Controls also has three joint ventures in the US with Tachi-S
supplying seats to Honda of America Manufacturing and Saturn. The takeover
is not expected to affect those ventures.
In September 20xx, Johnson Controls bought xx.x% of Ikeda Bussan’s xx.x
million shares and assumed $xx million in debt. Two months later, Johnson
Controls bought the remaining stake in the company, making it a wholly owned
subsidiary.
Faurecia’s acquisition of Sommer Allibert for €x.xx billion made the French
components group Europe's largest interiors supplier, increased its North
American market share overnight and elevated it to one of the few interiors
suppliers able to offer a complete interior anywhere in the world.
Magna, Johnson Controls, Visteon and Delphi Automotive Systems are all
missing one or more pieces from being a complete interior supplier.
System integration
CHAPTER TRUNCATED
25

The global market for automotive interiors - sample copy

Transcription

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