komatsu ntc’s operations€™s industrial machinery business and komatsu ntc (as of march 31,...
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1
Komatsu NTC’s Operations
September 16, 2014
Masayuki UegakiChairman of the Board
Komatsu NTC Ltd.
Investors Meeting (September 16, 2014)
2Komatsu’s Industrial Machinery Business and Komatsu NTC (as of March 31, 2014)
Defense Systems
Other
Komatsu NTC
KELK Komatsu Industries
Gigaphoton
Breakdown of sales: Komatsu NTC
Transfer machines48%
Machining centers8%
Grinding machines9%
Crankshaft millers10%
Wire saws8%
Laser cutting machines
5%
SubsidiariesIn Japan
and abroad12%
Sales: JPY73 bn
2008年~
ア
1992年~
NIPPEI TOYAMA EUROPE GmbH1996~
2004年~
2005年~NIPPEI TOYAMA(THAILAND)Co.,LTD
2008年~NIPPEI TOYAMA INDIA PRIVETE.,LTD
1963年~
1984年~
NTC AMERICA Corp.
1994年~2010年
1990 2000 2010
1950
1951~
1963年~
1984年~
2008年~
1938~
0 1970 1980
1945年~
Breakdown of sales: Industrial Machinery and Others
89.6% 10.4%
Construction, Mining and Utility Equipment
Industrial Machinery and Others
Breakdown of sales: KomatsuConsolidated sales: JPY1,953.6 bn Total sales: JPY203.9 bn
Japan
Abroad
NIPPEI TOYAMA Corporation Komatsu NTC Ltd.
Komatsu Ltd. Began production of machine tools for construction equipment (Industrial Machinery Div)
Komatsu Machinery Corp.
USA: Sales and service subsidiary of machine toolsEurope: Sales and service subsidiary of machine toolsChina: Sales and service subsidiary of machine toolsChina: Sales and service subsidiary of machine tools
Thailand: Sales and service subsidiary of machine toolsIndia: Sales and service subsidiary of machine tools
China: Manufacturing, sales and service subsidiary of wire saw parts
DALIAN BOHAI NIPPEI MACHINE TOOL Corporation
NIPPEI TOYAMA SHANGHAI TRADING Co., Ltd.
NTC (Changzhou) Semiconductor Equipment Co., Ltd.
Dai-NipponHeikiCo., Ltd.
Fukuno Steel Industry Co., Ltd. Toyama Machine Industry Co.,
Ltd.
Nippei Industrial Co., Ltd.
3Main Products
TECHNOLOGY & RELIABILITY
Our products make customer contributions in a variety of manufacturing processes of their automobiles.
New brand
Eternal Commitment to High Quality
Taking up the challenge of nanotopology
Engine-related partsCylinder headCylinder block
CamshaftCrankshaft
Solar panel
Connecting rod
4
Sales and operating profit by product
Profitability
Merger with Komatsu Machinery Corp.
NIPPEI TOYAMA Komatsu NTC
Transfer machinesWire saws
Machining centersLaser cutting machines
Grinding machinesOperating profit ratioCrankshaft millers
Subsidiaries (Japan & abroad)JPY in bn
140
120
100
80
60
40
20
Projected
5
35 GW210 GW
872 GW
2,019 GW
3,155 GW
0
1,000
2,000
3,000
2010 2020 2030 2040 2050
Markets
Increase of emission regulation-compliant cars→ Compact engines, hybrids, electric vehicles ⇒Increase in capital investment related to powertrain (engines and drive units)
Wire saws
Source: “Energy Technology Perspective 2012,” IEA
Electric vehicles
Fuel cell vehicles
Plug-in vehicles
Hybrid carsConventional gasoline cars
Fuel economy
Electric on the go
Compact engines
-20%
-10%
0%
10%
20%
30%
40%
0
20
40
60
80
100
120
'01 '03 '05 '07 '09 '11 '13 '15 '17 '19Production shift: Japan, USA & Europe Emerging countriesAverage annual growth of 5% worldwide but declining rate of growth
◆ Global demand for automobiles by powertrainIf the trend continues as it is today, gasoline-powered cars should peak out around 2040.
◆ Demand for automobiles by region
⇒ Steady capital investment related to automobile production
Machine tools
Source: Technology Roadmaps Solar Photovoltaic Energy (May 2010), IEA
◆ Long-range projection of solar cells
Cum
ulat
ive in
stall
ed P
V ca
pacy
(GW
)
☆If cost reduction advances, we can expect long-range growth of the market.☆We can also expect renewal demand.
[Preconditions]Power generation cost ≦JPY14/KWh
Due to overinvestment in facilities in 2011, demand remained slack in the following 3 years. The supply-and-demand balance has been corrected in 2014.
EPIA2017(Max.)projectionEPIA2017(Ave.)projectionEPIA2017(MIN.)projection
New
powe
r gen
erat
ion
(GW
)
◆ Short-term projection (solar panel installations)
Conversion of annual growth rate of 5 to 10 GW into the amount of wire saws: 700 to 1,400 units per year.
Million units Growth rate
YoY growth rate
Emerging countries
Japan
North America
Europe
Source: Global Market Outlook for Photovoltaics, EIPA
Source: IHS Automotive2014/6/30
6
Machine tools Wire saws
1) Growth of existing businesses
2) Structural reforms
Growth based on innovation1) Product development and differentiation
2) Expansion of business domain
Tasks
Development and launch of industry pacesetting DANTOTSU products by emphasizing environmental conservation, ICT, economy and safety
Development of products designed to meet next-generation powertrains (energy savings and compactness)
Development of next-generation products(by incorporating technologies designed to substantially cut down customers’ production costs)
Development of new markets
Businesses
Standardization (modularization), shortening lead-time from orders received to shipment
Expansion of parts and service operations
More applications of core technologies and products and business expansion in the supply chainProposals to improve customers’ productivity through ICT applications, and preventive maintenance
Reinforcement of operations in China, Asia and North America
Structural reforms: Improvements of SVCs and fixed costs, reinforcement of price and SVM management, and improvement of OVCs (claim expenses)
Reforms of procurement and production system
7Lead-time Reduction Efforts: Modularization of Customer-specified Parts
At present, we design parts specified by each customer, which makes it very difficult for us to improve lead-time, quality and costs.
Modularization
We will first consolidate models and promote modularization at the time of model changes.
1) Design man-hour:-70%
2) Design lead-time: 5 months ⇒ 2.5 months
Modularization of jibs as the next task⇒ Use of CAM
5) Manpower shift to development
3) Quality improvementImprovement of design quality by means of assessment In advance
4) Cost reduction・Reduction of SVCs by reviewing
design drawings.・Reduction of design expenses
Started in January 2014.
Projected reduction of design manpower for transfer machines and machining centers due to modularizationNote: Modularization is an important effort
of reforming production system.
(Parts applicable to modularization)
Man-hour comparison
New design Modularization-based design
DevelopmentProduction designRate of modularization
8Development Designed for Production Support Needs –Growing out of only selling machines-
By assessing how far we, a machine tool maker, can penetrate into customers’ production from the viewpoints of both maker and user, we will not only strive to develop new business models but also make contributions to Komatsu Group’s production reforms.
Core technologies
Applied technologies
Product develop-ment
【Lifecycle costs of Japanese automakers’ flexible transfer lines】
0
500
1,000
1,500
2,000
2,500JPY in mn
【Conditions for preliminary calculation】No. of machines: 10 units, cycle time: 3min (500units/month)Years of use: 10, Charge: JPY5,000/hour
Tool (control) expenses
Production control expenses
【Technology development for production support service】Engine
development Facilities review Production preparation Production
【Engine development and production flow】
Process design
Arrangement of facilities
Production of facilities
OperatorsTool
exchange
Maintenance
Quality control
Production control
Process improvement
NTC’s current domain
○Production support domain
【Development of production support technologies in collaboration with related departments of Komatsu】
【R&D operations】Manufacturing
Engineering CenterResearch Division
【NTC】
【Manufacturing Engineering Dept 】Engines at the Oyama Plant
・Energy saving・High speed・Tool monitoring・Machine maintenance・Machining
・Controllers・Adaptive technologies・Analysis technologies・Common network platform
Operation data
Performance validation
Adaptive control
Network platformNTC-developed key technologies
Process control data
・New controller ・Tools, machining technologies・Monitoring technology ・Analysis technologies
Production support technologies
・Process control・Preventive maintenance・Process improvement
“Users’ viewpoints”“Leading-edge technologies”
“Machinery maker”
“Difficult for NTC by itself”
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