TOYO TIRE & RUBBER Co., Ltd. (President and CEO: Kenji Nakakura) hereby announces its efforts for early earnings recovery for the business conditions in which we find ourselves. These conditions are expected to grow more stringent including deterioration in earnings for FY2008, due to a global downturn in the economy and the appreciation of the yen, along with our goals to build a manufacturing system to meet demands and structural reform.
Essential features are as follows;
- Build an appropriate manufacturing system meeting reduction of manufacturing
- Minimize spending with manufacturing selection at home and abroad, or selection of self-manufacturing or outsourcing
- Reform structure to survive even in the low growth age
It aims to improve business performance by FY 2010.
1.Build manufacturing system meeting demands
(1) Tire Business
- Review manufacturing systems at home and abroad
Build the optimum manufacturing system to streamline with shifting and integrating manufacturing products including overseas sites.
- Reduce employees in manufacturing operations meeting a reduction of manufacturing and transfer employees from administrative departments to manufacturing departments.
(2) DiverTech Business
- Improve manufacturing systems at home and abroad
Build the optimum manufacturing system to streamline with integrating domestic sites, building plants for after-service parts, shifting and integrating manufacturing products sites including overseas sites.
- Reduce employees in manufacturing operations meeting reduction of manufacturing and transfer employees from administrative departments to manufacturing departments.
- Reduce operations and shift operational system
(ex.) 8 hours ・2 shifts X 5 days/week → 10 hours ・1 shift x 4 days/week
* About 300 employees in manufacturing departments (5,100 employees as of the end of September, 2008) centering on irregular employees were reduced by the end of December, 2008. In addition, about 500 employees will be reduced by the end of March, 2009. (Total reduced numbers are 800 employees after the end of September, 2008)
* Moreover, about 800 employees will be reduced depending on car manufacturing plans for FY2009 and downturn in the economy.
2.Emphasize cash flow management
(1) Hold down facility investment (freeze and postpone)
- Investment plan of 104 billion yen in sum total for 3 years in the medium-term management plan ’08, starting in FY2008 is shrunk to 54 billion yen. Review enhancement plan in tire manufacturing capacity and maintain the current supply capacity.
* Reduce 48 billion yen form facility investment (tangible only) in sum total for 2 years, FY2009-2010.
- Hold down enhancement of TNA the 3rd phase manufacturing capacity and postpone building Asian manufacturing plant.
(2) Reduce inventory
- Reduce 4 billion yen from total inventory of tires by the end of March, 2010 in plants and sales companies at home and abroad.
(3) Cash out surplus assets and businesses
- Integrate sales sites, logistics sites and offices in Kansai areas and sell out the old sites.
(4) Strengthen credit management
*Interest-bearing debt is cut from 134.9 billion yen (As of at the end of December, 2008) to 120 billion yen at the end of March, 2011.
3.Enhance cost down activities
(1) Promote Global Cost Revolution (GCR) activities
- Spread Activities for reducing manufacturing costs (Project for time shortening
of vulcanization, procurement tools, rationalization of materials, and automation, tec.) globally in tires and DiverTech businesses
(2) Cost reduction (About 4 billion yen cut compared to FY2008)
- Reduce advertisement expenditures and sales promotion costs with the cancelling of events including Tokyo Motor Show etc., review TV commercials and outdoor advertisements and concentrate on our own ground, motor-sports activities.
- Reduce drastically both domestic and overseas business trips using TV or telephone conference systems. Business trips with stays in Japan are prohibited in principle. Reduce travel expenditures.
- Review and reduce all expenses including Halve executive cars, reduce drastically expense accounts, and shrink repair expenses (Stop construction projects at year-end and new-years, do it on weekdays).
(3) Shrink personnel costs with raising business efficiency (About a 2 billion yen cut compared to FY2008)
- Shrink personnel costs with a rise in business efficiency by business reform, reduce conference costs, overtime work and holiday work
- Reduce compensation for directors...Expand reduction after February, 2009 continuing from October, 2008
- Salary and annual bonus...Managers got reduced in second half of FY2008 and continue and expand reduction after FY2009
For members of the labor union, plan to negotiate with center of the labor union.
- Reduce about 200 employees from managers and administrative personnel including sales and technology of Toyo Tire & Rubber Co., Ltd. (1,900 employees as of the end of December, 2008) by the end of March, 2009, due to re-organization of full-time employees and the reduction of irregular employees.
- Build sales system meeting sales volumes and size to reduce about 200 employees at home and overseas sales subsidiaries (About 2,200 employees as of the end of December, 2008) by the end of March, 2010.
- Additional reduction of administrative personnel, assist manufacturing departments or brief shutdown could be considered depending on the future. demand trends.
4.Reform of management structure
(1) Speed up implementation through the management council (Newly constructed in November, 2008)
(2) Enhance functions of the board of directors and other committees (Newly constituted/ abolish).
*Speed up decision-making and conduct of affairs, and accelerate reform of management structure.
5.Review organizational control
(1) Streamline with integrating and reducing administrative departments
Tire business: Reduce 1 division and 2 departments
DiverTech business: Reduce 4 departments
Administrations and centers: Reduce 5 departments and 3 offices
(2) Newly construct original equipment sales division
Integrate the sales divisions of the DriverTech and tire business group.
(3) Newly construct a tire sales division
- Integrate domestic and overseas replacement tire divisions
- Spread the NITTO brand globally
(4) Selection and Focus of DiverTech business
- Enhance collaboration of anti-vibration rubber business
- Full-fledged spin off rigid polyurethane business into a separate company
Make a full-fledged start of sales, technological development and manufacturing activities at Soflan Wiz Co., Ltd. which specialized in urethane undiluted solution system, thermal insulation panels for the farming and livestock industries and ultra-low temperature rigid polyurethane form (including LNG tanks/tankers) from April, 2009.
- Finish withdrawing from urethane-based heat-resistant building construction material business by the first half of FY2009.
- Withdraw or assign inflatable life jacket business (Finished in September, 2008)
- Outsource production of some types of urethane mold products
(5) Reduce 10% of sites of domestic sales and logistics
(6) Organize businesses in subsidiaries and reform structures
- Sell out insurance agency businesses and integrate businesses in subsidiaries including real estate, recruiting and building maintenance
- Streamline and integrate subsidiaries of services
*Build a structure for lean operation to reduce manufacturing and business development.
The medium-term business plan ’08 is reviewed and drawn up at present.
*Soflan Wiz Co., Ltd.: Established in October, 2008
To integrate technological development, manufacturing and sales in the rigid urethane business, all were relegated to Soflan U-board Co., Ltd. Also, the company name was changed to Soflan Wiz Co., Ltd.