What are the frequent problems in Japanese parts manufacturing?

Recently, 13 companies involved in the falsification of Toray product data surfaced one after another, many of which were related to the automotive sector.

Prior to this, Torayhybrid Co., Ltd., a subsidiary of Toray Corporation of Japan, proactively exposed material data fraud scandals. It is reported that from April 2008 to July 2016, the heads of two Quality Assurance Offices of Toray HC changed the inspection data of products such as tire reinforcing agent and polyester industrial yarn to meet the requirements of customers when they produced inspection results. The value of Although Toray has improved its quality assurance system since October 2016, it has a total of 149 counterfeit incidents. The products involved have been sold to 13 companies and have flown into the Chinese market.

From Takadan Airbags, to Kobe Steel, to Mitsubishi Materials and Toray HC, important customers of these companies are in the automotive industry. Japan's parts manufacturing scandals frequently reveal what other issues are deeper.

â–  Data fraud once again affects the automotive industry

Thirteen customers who received Toray data counterfeiting products, including Bridgestone, Sumitomo Rubber, Yokohama, Toyo Tires, Hankook, Kumho, Nexans and other Japanese and Korean companies. According to industry experts, the polyester industrial yarn involved in data fraud is mainly used for the manufacture of automotive tire innerliner cords. The polyester industrial yarns used by all tire companies in Japan are manufactured by Toray HC.

According to reports by CCTV, the products covered by Toray data fraud have already flowed into the Chinese market. Zhang Hongmin, chairman of the Shandong Rubber Industry Association, said in an interview with a reporter from China Automotive News: “The domestic tire manufacturers have purchased polyester industrial yarns produced by European and American companies and local companies such as Xingda, and they rarely cooperate with Toray. However, it is not ruled out that there is a possibility that Toray's data fraud may involve products in the Chinese market."

It is understood that Toray is preparing to hire external experts to form a commission of inquiry and the data will be falsified as soon as possible during the year. Under the pressure of public opinion, many Japanese tire companies, such as Toyota Synthetics, Bridgestone, Yokohama Rubber, and Sumitomo Rubber, have stated that due to the long-standing violations, they will step up their efforts to lock in targeted products and confirm their safety.

On November 16th, Bridgestone filed a recall plan with the AQSIQ. It will take the initiative to recall some tires of Bridgestone's brand-resistant Chike specifications in China, totaling 225,511. The reason for the recall is that the product may have insufficient strength in the production process, especially if it is used under conditions of low air pressure and the tire is excessively deformed, the carcass curtain layout inside the tire may be broken, and the tire leakage may be caused when the tire is severe. Gas, there are security risks.

Some industry insiders speculate that Bridgestone’s recall may be related to its use of Toray Data fraud products. Whether this data fraud scandal will trigger a large-scale recall of tire companies is still uncertain.

â–  Problems with upstream companies cannot be prevented?

For a long time, as the leader and face of the Japanese manufacturing industry, Japanese auto parts are known for their precision manufacturing and reliable quality. The lean production method born in the rise of the Japanese auto industry is also regarded as an important part of modern quality management. It is also a target for Chinese auto and parts companies to learn and learn from.

Zhang Hongmin told reporters: “We were shocked after hearing a series of news. After all, Japan’s manufacturing has always had a high status in the minds of the people. These incidents have greatly damaged the existing image made in Japan. It should be said that Japan’s manufacturing has left the altar. ."

“Many companies involved in data fraud are multinational giants. Bridgestone as an example, its annual sales volume ranks first in the world, and its products cover the world.” A person in charge of a domestic tire company in China believes that although data fraud may not be correct, Product quality has a fatal effect, but this behavior itself is also detrimental to the brand value of Japanese parts suppliers.

Industry experts believe that Japan's spare parts manufacturing has frequently exposed data fraud scans, prompting people to start thinking about suppliers' control. Du Fangci, an advisor to the China Association of Automobile Manufacturers, suggested that in product R&D, zero-and-zero collaborative development and the development of more reasonable product quality standards can avoid similar incidents to some extent. "China's auto parts manufacturing must pay attention to product quality, and at the same time tighten the control over product quality and set up a corrective mechanism." However, he also said that vehicle companies have their own parts and components procurement control system, parts and components procurement There is also a set of quality standards for raw materials, but sometimes the upstream material industry is not able to do it. After all, it is separated by mountains.

â–  It is not desirable for quick success

Japan's manufacturing industry frequently exposes data fraud events, which may be related to the increased sense of crisis in the era.

“Japan has a large population and has few resources. Since its conception, it has always been hard work to survive, so the Japanese people’s pursuit of the ultimate spirit is praised by the world. Some Japanese products are quality benchmarks, such as automobile emissions testing equipment, the United States, etc. The country must purchase Japan," Du Fangci said in an interview with reporters. During these years, China’s manufacturing industry has developed rapidly. Many products have the world’s highest sales volume, and product quality is also catching up with advanced levels. The cost performance of Japanese products gradually loses its advantages. In addition, Japan is relatively inadequate in terms of innovation. For example, many time-honored companies have been eliminated by the times. Therefore, Japanese industry, including the parts and components industry, has a general sense of crisis.

Gu Yifan, senior advisor to the China Automobile Industry Association's brake commission and former secretary-general, also said: “Japanese cars are mainly economic, and competition among companies is fierce. At the same time, Japanese companies are facing competition from emerging forces such as South Korea and China. The pressure continues to be transmitted to upstream suppliers.” According to report, many Japanese auto parts and components companies have been forced to expand more external markets due to market pressure. However, Japanese auto manufacturing industry has always been a vertically integrated supply system. There is a great deal of tacit understanding among auto parts companies, but they are also limited by this relationship. "Whatever the reason, Japan's auto parts industry has exposed problems in its supply chain management," said Gu Yifan.

“Data falsification is a common phenomenon” and “How to make money without making fraud.” In the current case of data fraud in the Japanese manufacturing industry and the German automotive industry, the reporter found that domestic industry professionals seem to be accustomed to this behavior and even have some kind of “tolerance”. "Attitude. Zhang Weimin told reporters that the frequent scandals in Japanese manufacturing industry just gave China a good time to create a “curve overtaking”, but at the same time it also alerted the Chinese people, under any circumstances, to take improper measures to maintain the brand's leading position and seize market share. They are all undesirable. In the end, they may have to pay a high price for it.