Automotive Insourcing Investments Annual Greenfield Study, 2010 International Business Investing in America prepared by Content First, LLC - February 2011
Automotive Insourcing Investments Annual Greenfield Study, 2010 Contents Executive Summary 1 Greenfield Insourcing Projects Surge in 2010 2 Automotive Sector is Critical for Greenfield Investments 2 Automotive Greenfield Investments on the Rise 3 Japanese Companies Dominate Auto Greenfield Investments 5 Toyota Announces Most Auto Projects 6 Components Comprise Majority of Auto Greenfield Projects 7 Green Energy Plays Key Role in Auto Insourcing Projects 8 Auto Greenfield Investments Cluster in States With Car Assembly Plants 8 Top Five Auto Greenfield Projects by Jobs 10 Organization for International Investment (OFII) 1225 Nineteenth Street, NW Suite 501 Washington, DC 20036 telephone: (202) 659-1903 facsimile: (202) 659-2293 www.ofii.org
Executive Summary U.S. subsidiaries of global companies announced or opened over 1,300 new Greenfield projects in 2010, the largest number of planned projects by these companies for any year since fdi Markets 1 began tracking Greenfield projects in 2003. A Greenfield insourcing project is a capital investment to build a new plant, factory, or other business. In 2010, these projects increased by 20 percent from 2009. Ten percent of the 2010 Greenfield insourcing projects, or 139, were directly linked to automotive manufacturing or automotive- related investments. These projects generated an estimated $7.5 billion in capital investments, which comprised nearly 14 percent of all Greenfield investments. Car assembly factories, automotive components plants, and a variety of other projects directly tied to the final production of automobiles were among these new investments. U.S. Insourcing Greenfield Job Creation* - 2010 57,715 Jobs 47% *includes estimates 25,051 64,947 Jobs 53% Automotive Greenfield Job Creation* 2007-2010 12,336 18,078 Manufac turing All Other Industries 22,238 Top-Line Findings (2010) Total Greenfield Jobs: Greenfield insourcing projects created nearly 123,000 American jobs. Greenfield Manufacturing Jobs: Greenfield jobs in the manufacturing industry totaled nearly 65,000, representing 53 percent all Greenfield jobs. Automotive Greenfield Jobs on the Rise: Greenfield insourcing projects in the automotive sector alone created more than 22,000 jobs in the United States, up 20 percent over 2009. 2007 2008 2009 2010 *includes estimates Green Energy Auto Job Creation* - 2010 16,265 Jobs 73% *includes estimates 5,973 Jobs 27% Green Energy Auto Jobs Play a Major Role: More than one-quarter of all automotive employment or 6, 000 jobs were tied to green energy projects, with investments totaling $2.5 billion. Green Energy All Other Automotive 1
Greenfield Insourcing A total of 1,329 Greenfield projects or expansions were announced or opened in 2010, up by nearly 20 percent over 2009. This was the largest number of planned projects by global companies for any year since fdi Markets began tracking Greenfield projects in 2003. Cumulatively, fdi Markets has reported 6,537 Greenfield project or expansion announcements since January 2003. Projects Surge in 2010 Total U.S. Greenfield Employment Creation Estimates 2007-2010 122,662 106,508 99,063 97,537 2007 2008 2009 2010 New 2010 Greenfield projects represented an estimated $55 billion in total investments, creating nearly 123, 000 U.S. jobs. These Greenfield ventures by global companies contribute significantly to the U.S. employment base. In fact, each year from 2007 to 2009 Greenfield insourcing has generated around 100,000 American jobs. Manufacturing represented 53 percent of all Greenfield jobs, with 64,947 estimated in 2010. What is a Greenfield Insourcing Project? Every year, global companies and their U.S. subsidiaries announce plans for hundreds of new projects in the United States, known as Greenfield projects. Announcements or openings of Greenfield projects, along with expansions in existing U.S. subsidiaries operations by global companies, generate enormous economic benefits for the U.S. economy. Greenfield ventures bring billions of investment dollars into the United States, insource thousandss of American jobs, and highlight the importance of the U.S. market for global companies as a location for their business operations. Automotive Sector is Critical for Greenfield Investments Global auto manufacturers have increased their Greenfield investments considerably in the United States over the last year. The focus of this report is on the 139 automotive sector projects (consisting of automotive and auto-related manufacturing projects) announced or opened in 2010. 2 Two basic types of investments are covered. The first 2
is final car assembly manufacturing by companies such as Honda, Nissan, and BMW; the second is auto components manufacturing, which includes engines, chassis, car seats, tires, and other components necessary to produce an automobile. Projects for the production of auto components were included only if the majority of their output was producedd clearly for the auto manufacturing industry. Total Greenfield U.S. Job Creation* - 20100 100,424 Jobs 82% *includes estimates 22,238 Jobs 18% Automotive All Other Industries While this report focuses on the automotive industry, overall, Greenfield projects in 2010 were categorized into 39 distinct industry sectors. Software and Information Technology (IT) Services was the top industry by Greenfield projects in 2010 at 178, followed by Industrial Machinery, Equipment, and Tools (109), Business Services 109), and Financial Services (88). Automotive Greenfield Investments on the Rise One in ten Greenfield projects were directly linked to auto manufacturing in 2010. Some of these investments cover new, or expansions of, plants that manufacture cars, while others include various components used in the final assembly of cars, such as tires, axles, engines, seats, transmissions, and lithium-ion batteries for electric cars. Auto projects in 2010 were valued at an estimated $7.5 billion, which accounted for 14 percent of the $54.6 billion in announced Greenfield investments. These projects also created an estimated 22,238 American jobs, comprising 18 percent of all Greenfield jobs last year. The Greenfield auto sector is an important part of manufacturing. In fact, insourcing auto jobs accounted for 30 percent of all Greenfield manufacturing employment in 2010. Employment associated with these projects is a particular boon for communities where they locate because of their local multiplier effect. The United Automobile, Aerospace and Agricultural Implement Workers of America (UAW) estimates that one auto assembly job supports between 6 and 10 additional jobs, while one auto parts assembly job supports about 5.7 additional jobs. 3 Over the past few years, the number of auto sector projects has grown substantially by 56 percent from 89 announced projects in 2007 to 139 in 2010. Over 25,000 new jobs were announced in 2007, the most in the last four years. The number of jobs 3
dropped to 12,400 in 2008 and rose to 18,100 in 2009, well below the employment level recorded in 2007. Even with these ups and downs, there has been a steady stream of investments by global auto parts manufacturers over the past four years, which have included Japanese-headquartered manufacturers, such as Bridgestone, Kobe Steel, and Toyo Tire & Rubber. Bridgestone announcements included a technical center in Akron, Ohio, creating hundreds of jobs. Among Kobe Steel's announcements was another Ohio project; it involved a $475 million expansion of an automotive sheet steel factory. Toyo Tire established a state-of-the-art tire manufacturing plant and warehouse facility in White, Georgia, which employs hundreds of workers in the state. It is one of the hundreds of companies (both international and domestic) that comprise the extensive automotive supplier network in the Southeastern automotive corridor, which includes Alabama, Georgia, Tennessee, and South Carolina. Long-established global automotive manufacturers have also continued to announce new expansions in the United States, including Toyota, Honda, BMW, Daimler, and Nissan. Meanwhile, the South Korean automaker Kia opened a new leading-edge auto manufacturing plant in West Point, Georgia in 2010 and the German car manufacturer Volkswagen is currently finishing the construction of a new factory in Chattanooga, Tennessee, where production is slated to begin in 2011. Each of these investments, along with their supplier companies, is creating several thousand new jobs for U.S. workers. Auto Sector Greenfield Job Creation* 2007-2010 25,051 12,,336 18,078 22,238 2007 *includes estimates 2008 2009 2010 4
Japanese Companies Dominate Auto Greenfield Investments More than 40 percent of auto manufacturing Greenfield projects 56 of the 139 originated from manufacturers headquartered in Japan. Honda, Nissan, and Toyota are among the well-known Japanese manufacturers that announced new projects in 2010. Investments by other Asian manufacturers raised the total to more than half. South Korean manufacturers tallied 15 such projects; Hyundai alone had four projects, while CT&T announced plans for two electric car manufacturing plants in the United States. Chinese companies, which heretofore have not made many Greenfield investments, announced four projects last year, which could employ more than 400 workers in the United States. After Japan, Germany boasted the secondhighest number of auto Greenfield insourcing Auto Greenfield Projects by Country 2010 projects 26 in 2010. Several of the German projects are Europe Germany 26 Asia Japan 56 supplier companies France 7 South Korea 15 tied to the soon-to-beopened Volkswagen Sweden 3 Italy 6 China 4 Taiwan 2 plant in Tennessee, Austria 2 Total 77 while some others can Spain 1 be traced to the BMW Norway 1 North America factory in South Belgium 1 United Canada 11 Carolina. Three of the Kingdom 1 Mexico 2 seven Frenchheadquartered Total 48 Total 13 announcements were Middle East from PSA Peugeot- Israel 1 Citroen. Italian companies brought the third largest number of European auto projects (6) to the United States in 2010. In all, European companies accounted for 48, or 35 percent, of the auto Greenfield projects. In North America, Mexican-headquartered companies announced two Greenfield projects. Meanwhile, Canadian companies announced 11, eight of which were from the large auto components manufacturer Magna International. Additionally, one auto project was sourced from Israel. 5
Toyota Announces Most Auto Projects Ninety-five global companies announced auto sector investments in the United States in 2010. Several companies announced multiple projects. Toyota Motor was the top company with 11 projects, creating more than 500 jobs. Four Toyota projects established individual product quality offices, each dealing with a specific issue, such as hybrids or heating and cooling systems. Four additional Toyota projects were announced in Indiana to bolster its automotive assembly plant in the state. Canadian-based auto components manufacturer Magna International boasted the second highest number of projects; these eight projects ranged from production of roof systems and thermoset components to seats and gear boxes for electric cars. The locations for two Magna International projects were strategically chosen to be adjacent to the new Volkswagen plant under construction in Tennessee. A full detailed listing of all 139 projects is provided by OFII in a Projects Addendum to this report. Auto Greenfield Projects, 2010 (Ranked by Company) Company (Country) Projects Total Job Estimates Total Investments 1. Toyota Motor (Japan) 11 510 $120 Million 2. Magna International (Canada) 8 1,869 $380 Million 3. Hyundai (South Korea) 4 1,607 $505 Million 3. Volkswagen (Germany) 4 721 $332 Million 5. Honda (Japan) 3 180 $27 Million 5. Nissan (Japan) 3 3,086 $1.7 Billion 5. PSA Peugeot- Citroen (France) 3 684 $99 Million 5. Daimler AG (Germany) 3 696 $213 Million 6
Components Comprise Majority of Auto Greenfield Projects Components comprised 81, or nearly 60 percent, of all auto Greenfield projects in 2010. They are quite varied and demonstrate the numerous parts required to manufacture an automobile, ranging from mechanical parts, such as transmissions, crankshafts, and gear shifters to interior components, like seat adjusters, lighting, and trim. Second by number of projects is actual automobile manufacturing with one in five involving final assembly. Well-known car manufacturers, such as Hyundai, Toyota, Volvo, and Volkswagen announced new Greenfield projects in 2010, along with companies that are focused on the production of electric vehicles, such as South Korean-headquartered CT&T and British-based Tanfield. Global companies announced six auto Greenfield projects in both the chemicals industry and rubber industry. All the rubber industry projects are manufacturers of automotive tires, while the majority of the chemical industry projects revolve around the production of chemicals required in lithium-ion batteries for electric cars. The remaining projects were in various industries, such as plastics, metals, engines and turbines, and textiles. Auto Greenfield Projects by Industry, 2010 81 30 6 6 16 Components Automobiles Chemicals Rubber Other 7
Green Energy Plays Key Role in Auto Insourcing Projects The national and international focus on the environment has not gone unnoticed by the auto industry. In fact, the increased demand for hybrid and electric vehicles has produced a vibrant green energy subsector within auto manufacturing. Fifteen such green energy insourcing projects were announced in 2010. More than half are slated to produce lithium-ion batteries, which include announcements by Asian manufacturers like LG and Mitsubishi. Other projects include production of electric cars by manufacturers like CT&T. The economic impact of investments by these companies was significant in 2010. The estimated jobs created from thesee green energy projects was nearly 6,000, or more than one-quarter of all auto sector employment created. These investments totaled more than $2.5 billion, or one-third of the $7.5 billion in Greenfield auto projects. Green Energy Auto Job Creation* 2010 5,973 Jobs 27% Green Energy 16,265 Jobs 73% All Other Automotive *includes estimates Auto Greenfield Investments Cluster in States With Car Assembly Plants Auto sector Greenfield projects were announced in 25 states. Over 50 percent of these 139 Greenfield projects were in one of five states, all home to at least one major car assembly plant. Ranking first was Indiana, where Toyota and Subaru U.S..-based assembly plants are located, with 19 announcements in 2010. Michigan, long home to the Detroit Three U. S. auto manufacturers Ford, General Motors, and Chrysler as well as Japanese-headquartered Mazda, was the second largest recipient of Greenfield auto projects, followed by Alabama, where Honda, Hyundai, and Mercedes-Benz all have factories. Tennessee ranked fourth, with a Nissan plant and a new Volkswagen factory, followed by fifth-ranked Georgia, with Kia s new manufacturing plant. 8
As shown on the map below, the five states with the largest number of auto Greenfield announcements are highlighted in dark blue. South Carolina, where BMW has a car assembly plant, received six auto insourcing announcements last year, five of which emanated from German-headquartered companies. States with Automotive Greenfield Projects 2010 1-4 Projects 5-9 Projects 10+ Projects Note on Greenfield Project Announcements: The most recent statistics on announced Greenfield projects by global companies or their U.S. subsidiaries are reviewed in this report. All statistics are from fdi Markets, a database that tracks investment projects globally. While most Greenfield announcements result in actual new projects or expansions, sometimes plans are canceled or put on hold for a variety of reasons, including changes in market demand or other economic conditions affecting a company s business decisions. 9
Top Five Auto Greenfield Projects by Jobs 1. Greenfield Company: Nissan Location: Smyrna, Tennessee Jobs: 3,000 Investment: $1.7 Billion Company Headquarters: Japan Car (Part) Manufactured: Lithium-ion Battery Packs for Electric Cars Nissan announced in May 2010 that it intends to build a car battery factory, located next to its auto-assembly plant in Smyrna, Tennessee. The factory, which is expected to occupy some 1.3 million square feet, will produce lithium-ion battery packs for up to 200,000 electric cars when it becomes fully operational in 2012. The batteries will be installed in Nissan s LEAF, its all-electric, zero-emissions car. The $1.7 billion investment is estimated to create 1,300 local jobs. Some 250 construction jobs will be created to build the new factory. The $1.7 billion investment initially is being supported by a U.S. Department of Energy loan for 80 percent of that investment, up to $1.4 billion. The loan is part of a $25 billion Advanced Technology Vehicles Manufacturing Loan Program authorized by Congress as part of the Energy Independence and Security Act of 2007. "Tennessee has become a national leader in driving clean energy innovation, and Nissan's commitment to build this advanced-technology battery facility here in Tennessee is a key part of that success. Nissan's investment in Tennessee began more than two decades ago, and this new manufacturing plant leads the way to the next generation of automotive and clean energy jobs in the Volunteer state." Former Tennessee Governor Phil Bredesen 10
2. Greenfield Company: Magna International Location: Not Specified Jobs: 1,216 Investment: $250 Million Company Headquarters: Canada Car (Part) Manufactured: Lithium-ion battery packs for Electric Cars Magna International, Canada s largest auto components supplier, reportedly announced in May 2010 plans to establish a plant in the United States to manufacture lithium-ion batteries for electric vehicles. The investment announced is worth between $200 million and $300 million. In the same announcement, Magna said that it would build a similar factory in a yet to-be-determined site in the European Union. Initial reports were later clarified by Magna International Co-Chief Executive Officer Siegfried Wolf. Wolf said that while Magna continues to grow and is actively seeking opportunities in the electric battery business that several conditions still need to be met before any action is taken. Those conditions include, but are not limited to: sufficient market demand to justify the case for investment, conclusion of joint venture terms with technology partners, availability of financing, commercialization of related technologies, and the settlement of customer supply terms, including pricing and warranty matters. 3. Greenfield Company: ZF Friedrichshafen Location: Laurens County, South Carolina Jobs: 900 Investment: $350 Million Company Headquarters: Germany Car (Part) Manufactured: Fuel-Efficient Transmissions for Cars and Light Trucks German-based ZF Friedrichshafen, manufacturer of auto components, announced in July 2010 plans to establish a $350 million factory in Laurens County, South Carolina. The company chose this location from more than 12 states considered. The factory will produce fuel-efficient transmissions for cars and light trucks, employing 900 people when the factory is complete in 2015. 11
Further announcements by ZF confirmed that construction for the plant would begin in February 2011 in Greenville, South Carolina. Once complete, the factory will produce 8-speed automatic transmissions for Chrysler as well as 9-speed automatic transmissions. Currently, ZF employs some 5,100 workers at 20 sites in North America. "ZF's decision to make a jobs and capital investment of this magnitude, indeed the largest single infusion of jobs in the history of Laurens County, is an incredible compliment to our state. This announcement represents not only enormously good news for our state's economy, but also is a telling dividend from our continued efforts to better the business climate in South Carolina." Former South Carolina Governor Mark Sanford 4. Greenfield Company: Hyundai Location: Fountain Valley, California Jobs: 700 Investment: $150 Million Company Headquarters: South Korea Car (Part) Manufactured: Expansion of Hyundai s North American Headquarters Hyundai Motor USA, a subsidiary of South Korean carmaker Hyundai, announced in September 2010 that it plans to expand its North American headquarters in Fountain Valley, California. Hyundai will construct a new $150 million building on its current site, consisting of 500,000 square feet. Construction is set to begin in 2011 and when complete in 2012, staffing will increase from 700 to 1,400. As part of this office s operations, Hyundai product planners adapt their Korean products for the American market. These Hyundai Motor USA employees also work with the Hyundai manufacturing plant in Alabama to engineer automobiles for assembly. According to the Los Angeles County Economic Development Corporation, the two-year project will generate some 1,500 construction jobs with a $273 million total economic output. Today s announcements reiterate how our global economy directly and positively impacts California. Two of South Korea s top companies one of the largest automobile manufacturers in the world and a world-class airline have chosen California as a second 12
home. This means thousands of jobs for Californians at a time when they are needed most and an important boost to our local and state economies. Former California Governor Arnold Schwarzenegger (Former Governor Schwarzenegger used this opportunity to also comment on Korean Air s $1 billion investment in Los Angeles) 5. Greenfield Company: Daimler AG Location: Redford, Michigan Jobs: 624 Investment: $194 Million Company Headquarters: Germany Car (Part) Manufactured: Diesel Engines Daimler Trucks North America (DTNA) announced in June 2010 plans to invest $194 million to expand production of its diesel engine plant in Redford, Michigan. The project is expected to be completed in September 2011. The Michigan Economic Development Corporation contributed $56.8 million in economic incentives, in addition to other state and local tax credits and abatements. DTNA s subsidiary Detroit Diesel Corporation is a leading manufacturer of highway diesel engines for the commercial truck market. A big part of the investment will be spent on cylinder head production. The company will also redesign its manufacturing facilities, improve plant infrastructure, and purchase machines and equipment. Detroit Diesel s decision to invest in its Redford Township facility demonstrates that we are globally competitive. Our world-class skilled workforce, strong publicprivate partnership and manufacturing support systems make this a wise choice. This investment further solidifies Michigan s reputation as the place to be for domestic and international car and truck companies such as Daimler. Former Michigan Governor Jennifer Granholm 1 fdi Markets is an online database that has been tracking international direct investment projects worldwide since 2003. More information about fdi Markets can be found at http://www.fdimarkets.com. The statistics presented in this report were collected on February 1, 2011. 2 Automotive sector projects are found across various industries. Most are in automotive manufacturing or automotive-related components; others can found in metals, chemicals, and rubber. 3 Automotive Manufacturing Matters, UAW, http://www.uaw862.org/auto%20mfg%20fact%20sheet.pdf 13