Modulization in the Japanese Auto Parts Industry

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Business structures in car parts manufacturing firms are undergoing a transformation. Assemblers are demanding that their auto parts suppliers respond to global procurement needs, outsourcing, and modulization. In particular, assemblers want suppliers to provide modules, rather than discrete components. One reason for this trend is that cost paring on individual components is approaching its limit. In addition, assemblers are increasingly outsourcing parts as a means of easing the development-cost burden arising from stricter environmental and safety standards.There is no industry-wide definition of a "module". In its simplest form, a module is an assembly made up of different car parts. Typically, a module is made up of parts that require the interaction of different engineering disciplines. For example, bumper engineers design a bumper assembly only, but a front-end module requires coordination between bumper, lighting, cooling and body engineers.Many industry experts expect that the move to modular manufacturing will drastically shrink the number of Tier One suppliers. More and more suppliers are moving to undertake mergers or acquisitions as a way to increase capability to produce modules. In the future, there will simply be fewer suppliers in total. The race is on, globally.Modulization will result in increased capital expenditure, R & D costs, and investment burdens for the parts companies. It raises concerns that the total return on each company's invested capital will decline for structural reasons. In spite of these concerns, suppliers are left with no choice but to modulize: those that can't produce modules will lose control of their destiny, and perhaps even their companies.Megasuppliers have begun the recent rush to modulization, and continue to lead the way. "Black box" design proposals have been made for front-end, rear-end, or cockpit modules, and some are already supplied in domestic and overseas assembly plants. Suppliers are hoping to create modules that could be designed and developed in collaboration with automakers. As it happens, suppliers may eventually have a stronger voice in the design and development of car parts, a role traditionally left to the automakers.There is no telling how far automakers and suppliers may push the idea of modulization beyond 2003. One inevitable outcome will be a major shakeup in the supplier community which was established in the mid-1980s. After that, we may see suppliers moving not only to control their own destinies, but to create them.
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Modulization in the Japanese Auto Parts Industry

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