IHS Automotive SupplierBusiness Supplying Toyota Supplying the OEMs 2013 edition supplierbusiness.com
Contents Overview... 6 Global market overview... 6 Financial data... 6 Toyota financial overview... 7 Product and platform strategy... 8 Strategy review... 8 Major model programmes... 8 Corolla... 8 Camry...11 Prius... 13 Yaris/Vitz... 14 RAV4... 14 Etios... 15 Innova... 16 Tacoma & Tundra... 16 Land Cruiser...17 Hiace... 18 Platform strategy... 19 Major platforms... 20 1. MC-M (inc. Toyota Camry, RAV4, Prius, Highlander, Avalon, Avensis, Lexus RX)... 20 2. MC-C (inc. Toyota Corolla, Auris, Verso, Lexus CT, Scion tc, xb)... 21 3. IMV (Toyota Hilux, Fortuna, Innova)... 21 4. NBC2 (inc. Toyota Vitz/Yaris, Belta, Aqua)... 22 5. D91B (Daihatsu Mira, Tanto, Toyota Pixis)... 23 6. F2 (inc. Toyota Hilux, Land Cruiser Prado)... 23 7. J (inc. Daihatsu Terios and Toyota Avanza)... 23 8. EFC (Toyota Etios)... 24 9. F1 (inc. Toyota Land Cruiser (200), Tundra, Lexus LX)... 24 10. N (inc. Toyota Crown Royal, Crown Majesta, Lexus GS, LS)... 24 Component-sharing... 25 Volume planning... 25 Production strategy... 27 Production strategy overview... 27 Manufacturing network... 27 JAPAN... 29 NORTH AMERICA... 31 CHINA... 33 EUROPE... 35 INDIA & SOUTH-EAST ASIA... 36 LATIN & SOUTH AMERICA... 38 SOUTH AFRICA AND AUSTRALIA... 39 Internal supply network... 39 Modularisation strategy... 41 IHS Automotive SupplierBusiness COPYRIGHT NOTICE AND LEGAL DISCLAIMER 2013 IHS. No portion of this report may be reproduced, reused, or otherwise distributed in any form without prior written consent, with the exception of any internal client distribution as may be permitted in the license agreement between client and IHS. Content reproduced or redistributed with IHS permission must display IHS legal notices and attributions of authorship. The information contained herein is from sources considered reliable but its accuracy and completeness are not warranted, nor are the opinions and analyses which are based upon it, and to the extent permitted by law, IHS shall not be liable for any errors or omissions or any loss, damage or expense incurred by reliance on information or any statement contained herein. For more information, please contact IHS at customercare@ihs.com, +1 800 IHS CARE (from North American locations), or +44 (0) 1344 328 300 (from outside North America). All products, company names or other marks appearing in this publication are the trademarks and property of IHS or their respective owners. 2013 edition 2 2013 IHS
Supplier parks... 41 Cluster of reference... 42 Tokai... 42 Kanto... 44 Kansai... 45 Strategies for manufacturing efficiency... 46 Purchasing strategy... 48 Purchasing strategy overview... 48 Levels of vertical integration and outsourcing... 48 Purchasing organisation... 50 Purchasing offices... 50 Key purchasing personnel... 51 Purchasing budget... 51 Supplier selection... 52 Supply base development... 52 Major and strategic suppliers... 52 Supplier selection criteria... 53 Working with Toyota... 54 Global sourcing... 55 Policy and plans... 55 JAPAN... 55 NORTH AMERICA... 56 CHINA... 57 EUROPE... 57 Pricing policy... 58 Cost reduction programmes and strategies... 58 Payment process and terms... 59 Raw material price management... 60 Quality management... 61 Quality level... 61 Quality management systems... 61 Integration into product development... 62 Management of (suppliers and) sub-suppliers... 62 Supplier awards... 63 Technological positioning... 65 Areas of focus... 65 R&D spending... 66 R&D organisation... 67 Access to supplier technology... 68 Approach to alternative fuels, electrification and fuel cells... 68 Special vehicle development... 69 Interview... 71 OEM-Supplier survey results... 77 Introduction to the SuRe Index... 77 Methodology... 77 Executive summary... 77 Profit potential... 79 OEM LEVEL... 79 Organization... 80 OEM LEVEL... 80 Trust... 81 OEM LEVEL... 81 Pursuit of excellence... 82 OEM LEVEL... 82 2013 edition 3 2013 IHS
Outlook... 83 OEM LEVEL... 83 Global footprint... 86 Forward Model Program... 88 Major suppliers... 100 Toyota Highlander 2013... 100 Toyota Tundra 2013... 102 Toyota RAV4 2013... 103 Toyota Lexus ES 2012... 104 Toyota Corolla 2013... 105 Figures Figure 1: Global light vehicle sales, 2006-2012... 6 Figure 2: The Auris replaced the Corolla in Europe (hybrid version is pictured)... 10 Figure 3: The 11th generation of the Corolla was introduced in 2012... 11 Figure 4: The Toyota Camry remains the best-selling car in the United States... 12 Figure 5: Estimated Sales of Zero-Emissions Vehicles under the 2012 Amended Mandate in California 2018-2025... 15 Figure 6: Land Cruiser is Toyota s longest-running vehicle nameplate... 18 Figure 7: The Toyota Proace panel van is produced at PSA s Sevelnord plant in France... 35 Figure 8: Aisin Seiki Group Companies by Geographic Region... 49 Figure 9: Timeline of cost-reduction programmes at Toyota through 2011... 59 Figure 10: Integration of Quality in the product development plan of Toyota... 62 Figure 11: Orientation of Active Safety... 65 Figure 12: Toyota R&D Expenses... 67 Figure 13: The Toyota FCV-R Fuel Cell Concept... 69 Figure 14: Emin Atac, Toyota Motor Europe... 71 Figure 15: SuRe Index 2012 - Top of the Ranking... 78 Figure 16: SuRe Index 2012 - Middle of the Ranking... 78 Figure 17: 2012-2013 Profit potential results on scale... 80 Figure 18: 2012-2013 Organisatiojn results on scale... 81 Figure 19: 2012-2013 Trust results on scale... 82 Figure 20: 2012-2013 Pursuit of excellence results on scale... 83 Figure 21: 2012-2013 Outlook results on scale... 84 Figure 22: Toyota - Global assembly plant locations... 86 Figure 23: Toyota - Japan assembly plant locations... 86 Figure 24: Toyota - Forward Model Program 2012-2020... 89 Tables Table 1: Key Toyota financial performance values... 6 Table 2: Global annual sales for Toyota vehicle ranges covered in Major Model Programmes (2010-2018)... 19 Table 3: Forecast Top 10 most used platforms across global Toyota production, 2013 and 2018 (by model volume)... 20 Table 4: Global and Japanese Toyota production volumes (2007-2018)... 26 Table 5: Toyota and OEM affiliates - global production plants with forecast volumes (2013-2018)... 27 Table 6: Annual Toyota production (by plant) Japan (2009-2018)... 31 Table 7: Annual Toyota production (by plant) North America (2009-2018)... 33 Table 8: Annual Toyota production (by plant) China (2009-2018)... 34 Table 9: Annual Toyota production (by plant) Europe (2009-2018)... 36 Table 10: Annual Toyota production (by plant) India & South-East Asia (2009-2018)... 37 2013 edition 4 2013 IHS
Table 11: Annual Toyota production (by plant) Latin & South America (2009-2018)... 39 Table 12: Annual Toyota production (by plant) South Africa & Australia (2009-2018)... 39 Table 13: Toyota Group Companies... 40 Table 14: Supplier manufacturing plants in Tokai... 42 Table 15: Supplier manufacturing plants in Kanto... 44 Table 16: Supplier manufacturing plants in Kansei... 45 Table 17: Denso revenues by region 2008 2012... 52 Table 18: TEMA 2012 Supplier Awards... 63 Table 19: Toyota Domestic and Overseas R&D Bases... 67 Table 20: SWOT analysis - Toyota... 85 Table 21: Toyota plant locations with production forecast for 2013... 87 Table 22: Toyota Highlander 2013 Supplier Data... 100 Table 23: Toyota Tundra 2013 Supplier Data... 102 Table 24: Toyota RAV4 2012 Supplier Data... 103 Table 25: Toyota Lexus ES 2012 Supplier Data... 104 Table 26: Toyota Corolla 2013 Supplier Data... 105 2013 edition 5 2013 IHS