Design your passion with TOYOTA · PDF fileWe introduce training methods so that people who...

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CORPORATE PROFILE with TOYOTA BOSHOKU Design your passion

Transcript of Design your passion with TOYOTA · PDF fileWe introduce training methods so that people who...

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C O R P O R AT E P R O F I L E

with TOYOTA BOSHOKUDesign your passion

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Production entities

Toyota Boshoku plantsProduction subsidiaries Other subsidiariesAffiliates

Global Mainstay HubOptimal global

business operations

China RegionToyota Boshoku (China) Co., Ltd.

The AmericasRegion

Toyota Boshoku America, Inc.

RM&CH

Europe & Africa Region

Toyota Boshoku Europe N.V.

Asia & OceaniaRegion

Toyota Boshoku Asia Co., Ltd.

Japan RegionToyota Boshoku Corporation

One Hub per Region

The Toyota Boshoku group has created a “one hub per region” structure in order to carry out optimal procurement, optimal manufacturing and optimal business operations throughout the world. Along with close coordination between the RM&CH and the Global Mainstay Hub, RM&CH work together with production entities in respective regions as part of the “one hub per region” structure.

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As a system supplier committed to the total creation

and coordination of automobile interiors and as a

manufacturer specialising in filters, the Toyota

Boshoku group aims to become a company that per-

sists in proposing excellent mobility for customers the

world over.

We always try to look at things through the eyes of

our customers so that we can deliver what customers

truly desire, namely, products that are useful, attrac-

tive, environmentally friendly, affordable and one

step ahead of the times. Our mission is to create and

provide inspirational products that exceed customers’

expectations.

In order to provide eye-catching products to cus-

tomers around the world in a timely manner, we seek

to integrate Toyota Boshoku’s unique technologies

with accumulated know-how in high-productivity

manufacturing. By doing so, we can develop even

more advanced and higher quality manufacturing.

We aim to be a truly global company trusted by all

stakeholders and which promotes sustainable growth

in harmony with society as a good corporate citizen

while contributing to society through manufacturing

that brings joy to customers.

Yoshimasa IshiiPresident

Shuhei ToyodaChairman

Aiming to be a truly global company that promotes sustainable growth in harmony with society as a good corporate citizen while contributing to society through manufacturing

CORPOR ATE PROFILE

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TOYOTA BOSHOKU Group at a GlanceOutline of Toyota Boshoku Group

The Toyota Boshoku group divides its bases into five regions of the world, specifically The Americas, Asia & Oceania, China, Europe & Africa and Japan. The operation of integrated production entities is carried out within each region, with the Regional Management & Collaboration Hubs serving as the core of operations.

http://www.toyota-boshoku.com/globalPlease visit our website for the latest information:

lRegional Management & Collaboration HubsnMain entities

Net sales (Millions of yen) Operating income (Millions of yen) Ordinary income (Millions of yen) Corporate Profile HistoryName TOYOTA BOSHOKU CORPORATION

Business operations (1) Development of automotive interior systems; and the manufacture

and sale of automotive interior products

(2) Manufacture and sale of automotive filters and powertrain components

(3) Manufacture and sale of other automotive components

(4) Production and sale of textile goods

Representative Shuhei Toyoda, Chairman Yoshimasa Ishii, President

Capital 8.4 billion yen

Founded 1918

Established 1950

Location 1-1 Toyoda-cho, Kariya-shi, Aichi

1918 Toyoda Boshoku Corporation founded

1943 Merged with Toyota Motor Co., Ltd. (currently Toyota

Motor Corporation)

1950 Minsei Spinning Co., Ltd. established as a separate

entity from Toyota Motor Co., Ltd. (currently Toyota Motor Corporation)

1967 Company name changed to Toyoda Boshoku

Corporation

2000 Merged with Toyota Kakoh Co., Ltd.

2004 Merged with Araco Corporation (car interior operations)

and Takanichi Co., Ltd. Company name changed to Toyota Boshoku Corporation

Japan

TOYOTA BOSHOKU CORPORATION

The Americas

TOYOTA BOSHOKU AMERICA, INC.

Note: Sales amounts per region are stated prior to consolidated elimination.

Net sales by geographic region (Year ended March 31, 2016)

Unit: Millions of yen

Years ended March 31

96,564Europe & Africa

726,264Japan

316,406The Americas

357,208Asia & Oceania (including China)

Approximately 50,000 more than Toyota Boshoku group company members around the world are committed to the creation of attractive products.

CORPOR ATE PROFILE

Asia & Oceania

TOYOTA BOSHOKU ASIA CO., LTD.

Europe & Africa

TOYOTA BOSHOKU EUROPE N.V.

201620152014201320120

300,000

600,000

900,000

1,200,000

1,500,000

1,305,502

1,415,772

1,218,399

1,079,497

964,295

201620152014201320120

15,000

30,000

45,000

60,000

75,000

32,39328,823

25,302

20,910

59,492

201620152014201320120

15,000

30,000

45,000

60,000

75,000

41,09140,294

33,914

23,225

56,123

China

TOYOTA BOSHOKU (CHINA) CO., LTD.

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Electric sunshade systemsInterior systems

Door trims

Leather instrument panels

Headliner illuminationsHeadliners

Floor carpets

Package trays

Silencers

Seats

Curtain-shield airbags

Fender liners

Strap belts and Seatbelt webbings

BumpersIntake manifolds(For horizontally opposed engine)

Cabin air filtersOil filtersAir filters Oil mist separators

Air induction systems

By developing engine intake parts such as the air cleaner, intake manifold and cylinder head cover as a single system, weight reduction and a more compact design are realised while also contributing to improved engine performance.

Cylinder head covers

Motor core constituent parts(For hybrid system)

Seat fabrics

Aircraft seats Railway seats (Photo provided by East Japan Railway Company)

New Category

Seat frames

Separators(Fuel cell parts)

Stack manifolds(Fuel cell parts)

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We deliver high value-added products to customers all around the world.

Product Lineup

CORPOR ATE PROFILE 65

Interior ComponentsToyota Boshoku takes a comprehensive approach in developing the entire concept of interior spaces, from the development stage to design, procurement and production, as an interior system supplier for automobile manufacturers. In our pursuit to achieve comfortable, safe and attractive interiors, we provide integrated and effectively coordi-nated interior space systems comprised of seats, door trims, headlin-ers, floor carpets and other components.

Textiles and Exterior ComponentsIn the textile business, one of our original businesses, Toyota Boshoku develops materials such as seat fabrics, fabrics for airbags and cabin headliner materials while undertaking concerted efforts that give full consideration to creating environ-mentally friendly products.

Also, in the exterior components business, we manufacture bumpers, fender liners and engine undercovers.

Filtration and Powertrain Components Using world-leading filtration technology, Toyota Boshoku produces air induction system products, lubricating system products for engines such as oil filters with replaceable elements, vehicle air conditioning filtration system products, fuel cell parts, and other products. Toyota Boshoku is working to develop and manufacture even higher added-value products that match the needs of society, including products that deliver enhanced performance and lower costs as well as modularised, systemised and environmentally friendly responsive products with improved comfort.

CORPOR ATE PROFILE

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For us, ideal manufacturing reflects a commitment to produce products of the highest quality that meet customers’ expectations and enrich their mobility life.

We aim to carry on the spirit of our founder Sakichi Toyoda who strongly believed in the thorough, repeated testing of products and only sent products to market that had been perfected. He believed that “A product should never be sold unless it has been tested thoroughly and satisfactorily.” With this in mind, we always focus on realising advanced, high-quality manufacturing.

Manufacturing

Fully leveraging manufacturing

Carrying on the spirit of our founder and focusing on quality

Creating innovative technologies that distinguish us from our competitors

Aiming to create optimal production lines through kaizen (continuous improvement)

Enhancing manufacturing capabilities by transferring skills

Toyota Boshoku’s origins date back to when Sakichi Toyoda, the first person in Japan to invent the automatic loom, established a cotton-spinning factory to fully develop the features and performance of the loom and produce top-quality thread. Sakichi, who always sought to develop technologies that were at the vanguard of the times and succeeded in creating a number of inventions, had a strong conviction in the thorough, repeated testing of products, and that only perfected products should be sent to market. He believed that “A product should never be sold unless it has been tested thoroughly and satisfac-torily.” We carry on that spirit as we work to comprehensively enhance quality levels.

As a global manufacturer, we work to integrate developmen-tal technology, production technology and production processes in our manufacturing system, which includes creating technical drawings that incorporate quality factors from the design stage in addition to improving quality at the manufacturing stage.

Besides meeting the demands of automakers and complying with the laws of different countries and regions, we conduct manufacturing that places an emphasis on quality based on our own regulations and standards.

In order to efficiently make value-added products, we work to develop unique core production technologies and enhance our technological capabilities by making constant improvements.

For instance, in the precision press field, we significantly enhanced quality and accuracy as well as production efficiency for round recliners for seats (a precision part comprised of a reclining structure that alters the seat angle) through the development of the Fine Hold Stamping (FHS) method, an advanced technology that even speciality manufacturers cannot emulate. In addition, we have achieved higher added value and efficiency in the production of elements for cabin air filters that cleanse the air of particles by employing the melt-blow method.

By further developing new core technologies and making production equipment even more compact, we aim to further improve production technologies. Further, we will create inno-vative technologies that distinguish us from the competition by integrating core technologies that have been developed and matured in such fields as seats, interior components, filters, powertrain components and textiles and by actively pursuing the expansion of technological domains.

Toyota Boshoku continuously works to create highly efficient production lines by undertaking kaizen activities on a daily basis. Rather than relying on our achievements to date, we repeatedly say that even the latest production line is not the best it can be and constantly undertake efforts to improve productivity.

Our aim is to create simple production lines with minimal processes that require fewer man-hours and are streamlined. These lines only produce what is needed, when it is needed and in the quantity needed according to the Just-In-Time concept. We strive to create production lines that are compact, waste-free and highly productive. Through constant improvements, our ultimate goal is to create optimal, all-purpose lines that can produce a range of products on a single line.

Going forward, we seek to create a global production system that meets customers’ needs anywhere in the world by intro-ducing the initiatives implemented in Japan to other regions.

In order to carry out leading-edge, high-quality manufacturing on a global basis, we share the Toyota Boshoku manufacturing spirit with its focus on quality, as well as advanced skills devel-oped in Japan, with our group companies around the world.

We introduce training methods so that people who come from different cultures and speak other languages can master our manufacturing customs and develop skills they can use as leaders. For instance, members in group companies that re-ceived education and training in Japan help nurture younger local personnel in respective regions.

We aim to spread both Japanese and Toyota Boshoku manu-facturing around the world as a means to strengthen our global manufacturing competitiveness.

Assembly line for seats at the Sanage Plant

Passing on skills in each region of the world (South Africa)

Melt-blow method used to produce two layers of fine fibres on the same production line

Toyota Boshoku is committed to ensuring top quality in every production process.

Making consistent improvements through genchi-genbutsu (Go, see & study)

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TB Way

Respect for the individual

Open mind and a global perspective

Continuously carrying out kaizen

Move quickly

Good corporate citizenGenchi-genbutsu (Go, see & study)

Challenges

Professionalism

Values, stance and action

Practical training on mould finishing (Toyota Boshoku Technical Skills Academy)

Company members from around the world compete at the All TB Skills Competition.

Master Trainer Programme

Helping to raise skills to enhance workplace competencies

In teaching specialised skills, we established the Toyota Boshoku Technical Skills Training Centre to develop human resources who can enhance workplace competencies around the world. Company members from all corners of the globe gather here to learn fundamental manufacturing skills before communicating what they have learned to their respective regions, thereby raising skills worldwide. In the skills training and recognition system, depending on such factors as their years of experience, members start from the basics to learning skills at the applica-tion level via genchi-genbutsu, with the aim of systematically gaining knowledge and skills required at the workplace. The training is used to increase capabilities at three levels, specifi-cally in terms of common knowledge, specialised knowledge and practical skills.

Meanwhile, the All TB Skills Competition is held every year for company members from different parts of the world to compete against each other.

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In order to provide opportunities for growth to all company members working in the Toyota Boshoku group, we are expanding and enhancing various human resources development programmes.

We are always committed to nurturing global human resources to ensure swift response to changes in automobile-related environments and the expansion of global business.

Human Resources Development

Nurturing personnel capable of taking an active role globally

Developing global human resources by sharing the TB Way

Developing diverse human resources through education and training programmes

In addition to developing personnel who play an active role globally, we are promoting the development of regional mem-bers based in respective regions by strengthening the education and training of locally recruited personnel.

A common element of human resources development is understanding and practicing the TB Way. This involves sharing the values and behaviour espoused by the TB Way and making sure the fundamental philosophy underpinning the TB Way of “contributing to society by developing leading-edge technolo-gies and manufacturing high-quality products” is fully under-stood. We also aim to increase company members’ overall capabilities from two perspectives. First, from an individual standpoint, we encourage personnel to trust in and exercise their ability to think independently. Second, from a team perspective, we pursue mutual growth for both the Company and members based on mutual trust and accountability.

Global Trainee System

A wide variety of personnel learn together and grow together.

Designed to heighten global awareness and language skills, this system provides employees with opportunities to work in foreign countries through short-term (one- to two-year) person-nel transfers among companies within the Toyota Boshoku group. The program enhances capabilities in development, production engineering, production control, quality assurance, and other human resource functions, strengthens communica-tions skills to be active internationally, and develops personnel ready to act as the leaders of tomorrow.

Master Trainer ProgrammeThis programme aims to cultivate trainers who can teach problem solving, on-the-job training (OJT) and policy manage-ment based on the TB Way. They are held at regular intervals in Japan to develop trainers who will be active in their regions of the world.

CORPOR ATE PROFILE

The Toyota Boshoku group has created an education and training system in each region aimed at increasing skills from various perspectives. This system can be broadly divided into three areas: (1) “Training by job classification,” which is applicable to everyone from new recruits to division directors; (2) “Profes-sional training,” which is mainly for functional divisions related to such areas as technology, quality and finance; and (3) “Self-development,” which includes English conversation lessons and correspondence courses, among others.

Moreover, at Toyota Boshoku Technical Skills Academy in Japan, which aims to foster young leaders for the workplace, personnel learn the fundamentals of machine systems and electrical systems through basic practical training on material mechanics and circuit diagram production. At the same time, we develop human resources who have a global outlook and a profound awareness of the need for cooperation and camara-derie as well as a good balance between mind, body and spirit. We achieve this through teaching business etiquette, global education and living in dorms during the programme.

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Promoting corporate growth while fulfilling our responsibilities as a good corporate citizen

In order to earn and maintain the trust of society as a good corporate citizen, we strive to further permeate compliance. We are seeking to put into practice our corporate philosophy of “promoting corporate growth while fulfilling our responsibili-ties as a good corporate citizen” by increasing each company member’s awareness of compliance based on the Toyota Boshoku group code of conduct and by providing guidance to ensure members use appropriate judgment and act responsibly.

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We promote corporate social responsibility (CSR) as a global company aiming to realise corporate growth in harmony with society as a good corporate citizen while contributing to society through manufacturing. In order to meet the expectations and trust of all stakeholders, we comply with laws, regulations and ethics and seek to ensure highly sound, transparent and efficient management.

Corporate Social Responsibility

Meeting the expectations and earning the trust of society as a good corporate citizen

Reforestation project in Southeast Asia

Establishing a dynamic, motivating environment for everyone

Global efforts regarding environmental issues

The Toyota Boshoku group holds events that enable company members to interact with each other. Besides the Global Ekiden (relay road race) for group companies worldwide, a regatta and summer festivals are held in Japan.

Local residents in addition to Toyota Boshoku group members and their families participate in these events, which play an important role in creating a bridge between the Company and local communities. We also strive to instil a sense of unity in each workplace and deepen exchange between business entities to create a dynamic and motivating environment for Toyota Boshoku members.

We promote environmental protection in all areas of our business activities and work to resolve environmental issues globally as a unified group. By reducing environmental loads through eco-friendly development, design and production, we pursue the potential of our environmental technologies. We do this by making automobile interior components lighter to enhance fuel efficiency and by employing plant-derived materi-als to reduce CO2. We create products that are both comfort-able and ecologically responsible by maximising the potential of our environmental technologies in order to contribute to the realisation of a sustainable society.

Additionally, we are promoting sustainable factory activities over the medium to long term that aim to use nature to create factories in harmony with the natural environment. This involves working to reduce CO2 via the three key themes of “Eco-innovation,” “Eco-energy” and “Eco-communication.”

Solar power generation system (Gifu Plant)

Natural lighting system (No. 2 building of the Sanage Development Centre)

Global reforestation activities (Kashimo, Nakatsugawa City, Gifu Prefecture)

Toyota Boshoku group Global Ekiden (relay road race)

Global environment cleanup campaign activities (Toyota Boshoku Foshan Co., Ltd.)

Regatta

Bringing smiles to more faces through regional social contribution activities

Toyota Boshoku promotes social contribution activities focused on the environment, nurturing youth and education in each of the regions where we operate, namely The Americas, Asia & Oceania, China, Europe & Africa, and Japan.

We aim to bring more smiles to faces the world over by actively promoting welfare and activities with local citizens that are suited to the needs of respective regions.

Thorough reinforcement of risk management

The Toyota Boshoku group has created an effective manage-ment system in order to respond swiftly to management risk, risk in daily operations and other risks such as disasters and accidents. We also endeavour to predict and prevent damage and minimise the impact should a crisis occur.

In addition, we set up the Large-Scale Disaster Countermea-sure Committee and Emergency Operation Centre (EOC) and further strengthened collaboration between the functions of the Global Mainstay Hub and Regional Management & Col-laboration Hubs (RM&CH), which has served to reinforce the crisis management system of the entire group.

Evacuation drills to assume large-scale disasters

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The Americas Asia & Oceania China

Regional Management & Collaboration Hub

U.S.A.

1 TOYOTA BOSHOKU AMERICA

Production entities

U.S.A.

2 SYSTEMS AUTOMOTIVE INTERIORS

3 TBDN TENNESSEE

4 TOYOTA BOSHOKU ILLINOIS

5 TOYOTA BOSHOKU INDIANA

6 TOYOTA BOSHOKU KENTUCKY

7 TOYOTA BOSHOKU MISSISSIPPI

8 TOYOTA BOSHOKU TENNESSEE

9 TB KAWASHIMA USA

Canada

10 TOYOTA BOSHOKU CANADA

Mexico

11 TB SEWTECH DE MEXICO

12 TB KAWATEX DE MEXICO

Brazil

13 TOYOTA BOSHOKU DO BRASIL

Argentina

14 TOYOTA BOSHOKU ARGENTINA

15 SEWTECH ARGENTINA

Regional Management & Collaboration Hub

Thailand

1 TOYOTA BOSHOKU ASIA

Production entities

Thailand

2 BOSHOKU AUTOMOTIVE (THAILAND)

3 S.K. AUTO INTERIOR

4 STB TEXTILES INDUSTRY

5 THAI SEAT BELT

6 TOYOTA BOSHOKU FILTRATION SYSTEM (THAILAND) 7 TOYOTA BOSHOKU GATEWAY (THAILAND)

8 TOYOTA BOSHOKU SIAM METAL

9 TB KAWASHIMA (THAILAND)

India

10 TOYOTA BOSHOKU AUTOMOTIVE INDIA

11 TOYOTA BOSHOKU RELAN INDIA

12 TB KAWASHIMA AUTOMOTIVE TEXTILE (INDIA)

Indonesia

13 TOYOTA BOSHOKU INDONESIA

14 ATEJA KAWASHIMA AUTOTEX

Malaysia

15 TOYOTA BOSHOKU UMW

Philippines

16 TOYOTA BOSHOKU PHILIPPINES

Taiwan

17 SHIN SAN SHING

Vietnam

18 TOYOTA BOSHOKU HAIPHONG

19 TOYOTA BOSHOKU HANOI

Australia

20 TOYOTA BOSHOKU AUSTRALIA

21 TB KAWASHIMA AUSTRALIA

22 AUSTRALIAN FABRIC LAMINATORS

Laos

23 TOYOTA BOSHOKU LAO

Pakistan

24 THAL BOSHOKU PAKISTAN

Regional Management & Collaboration Hub

China

1 TOYOTA BOSHOKU (CHINA)

Production entities

2 CHANGCHUN FAWAY TOYOTA BOSHOKU AUTO PARTS

3 CHENGDU TOYOTA BOSHOKU AUTOMOTIVE PARTS

4 FENG'AI (GUANGZHOU) AUTO SEAT PARTS

5 GUANGZHOU INTEX AUTO PARTS

6 HEYUAN TOYOTA BOSHOKU AUTOMOTIVE PARTS

7 KUNSHAN TOYOTA BOSHOKU AUTOMOTIVE PARTS

8 NINGBO ARACO

9 QINGDAO INJELIC MOULD

10 SHANGHAI TOYOTA BOSHOKU AUTOMOTIVE PARTS

11 SHENYANG TOYOTA BOSHOKU AUTOMOTIVE PARTS

12 TIANJIN FENG'AI AUTOMOTIVE SEAT PARTS

13 TIANJIN INTEX AUTO PARTS

14 TIANJIN KAHOU AUTOMOBILE DECORATION

15 TIANJIN TOYOTA BOSHOKU AUTOMOTIVE PARTS

16 TOYOTA BOSHOKU FOSHAN

17 KAWASHIMA TEXTILE MANUFACTURES (SHANGHAI)

18 SEIWA SEAT COVERS (BENGBU)

19 SHANGHAI KAWASHIMA SHENDA DYEING AND FINISHING

1

43

2

95

6

1110

8

7

JapanEurope & Africa

12

145

418

TOYOTA BOSHOKU KYUSHU

TOYOTA BOSHOKU SHIGA

1715

Aichi Prefecture

110

211

312

613

716

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TOYOTA BOSHOKU TOHOKU

Regional Management & Collaboration Hub

Belgium

1 TOYOTA BOSHOKU EUROPE

Development site

Italy

2 TOYOTA BOSHOKU MILAN DESIGN BRANCH

Production entities

France

3 TOYOTA BOSHOKU FRANCE

4 TOYOTA BOSHOKU SOMAIN

Poland

5 TBAI POLAND

6 TBMECA POLAND

Russia

7 TOYOTA BOSHOKU

Slovakia

8 TRIM LEADER

Czech

9 MEGATECH BOSHOKU EUROPE

Turkey

10 TOYOTA BOSHOKU TURKEY

11 TB SEWTECH TURKEY

South Africa

12 TOYOTA BOSHOKU SOUTH AFRICA

Global Mainstay Hub

1 Global Mainstay Hub

Plants and Offices in Japan

1 Kariya Plant

2 Oguchi Plant

3 Kisogawa Plant

4 Inabe Plant

5 Gifu Plant

6 Sanage Plant

7 Fujioka Plant

8 Takaoka Plant

9 Tsutsumi Plant

10 Toyohashi-Kita Plant

11 Toyohashi-Minami Plant

12 Toyohashi-Higashi Plant

13 Tahara Plant

14 Fujisusono Plant

15 Tokyo Plant

16 Tsuchihashi Plant

17 Tokyo Office

18 Osaka Marketing Office

Production Entities

Subsidiaries

ARACO

COWERK

TOYOTA BOSHOKU KYUSHU

TOYOTA BOSHOKU SHIGA

TOYOTA BOSHOKU TOHOKU

TB SEWTECH KANTO

TB SEWTECH KYUSHU

TB SEWTECH TOHOKU

TB KAWASHIMA

SEIWA

Affiliates

TOKAI CHEMICAL INDUSTRIES

TOYOTA BODY SEIKO

NARUCO

HIGH NEED INDUSTRY

Others

TB ENGINEERING

TB CREATE STAFF

TB CORPORATE SERVICE

TB TECHNOGREEN

TB LOGISTICS SERVICE

TB UNIFASHION

TECHNICAL LINKS DESIGN

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TOYOTA BOSHOKU Group NetworkList of Toyota Boshoku Group Sites by Region

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101918

6 17

79

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2

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1 8

17

15

16

181923

13 14

20 2122

1012

24

1 639 74 85 2

11

4 5

27

18 3 9

610

1211

131415

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1-1 Toyoda-cho, Kariya-shi, Aichi 448-8651, Japanhttp : //www.toyota-boshoku.com/global

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