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AUTO COMPONENT INDUSTRY REPORT
‐ By Dun & Bradstreet India
OVERVIEW OF AUTO COMPONENT INDUSTRY
The Indian auto component industry has been navigating through a period of rapid
changes with great élan. Driven by global competition and the recent shift in focus of
global automobile manufacturers, business rules are changing and liberalisation has had
sweeping ramifications for the industry. The global auto components industry is estimated
at US$1.2 trillion. The Indian auto component sector has been growing at 20% per annum
since 2000 and is projected to maintain the high‐growth phase of 15‐20% till 2015.
The Indian auto component industry is one of the few sectors in the economy that has a
distinct global competitive advantage in terms of cost and quality. The value in sourcing
auto components from India includes low labour cost, raw material availability, technically
skilled manpower and quality assurance. An average cost reduction of nearly 25‐30% has
attracted several global automobile manufacturers to set base since 1991. India’s process‐
engineering skills, applied to re‐designing of production processes, have enabled
reduction in manufacturing costs of components. Today, India has become the outsourcing
hub for several global automobile manufacturers.
Innovation and cost pruning hold the key to meeting the global challenge of rising demand
from developed countries and competition from other emerging economies. Several large
Indian auto component manufacturers are already gearing to this new reality and are in
the process of substantially investing in capacity expansion, establishing partnerships in
India and abroad, acquiring companies overseas and setting up greenfield ventures, R&D
facilities and design capabilities.
Some leading manufacturers of auto components in India include Motor Industries
Company of India, Bharat Forge, Sundaram Fasteners, Wheels India, Amtek Auto,
Motherson Sumi, Rico Auto and Subros. The India’s Top 500 Companies, published by Dun
& Bradstreet in 2006, listed 22 auto component manufacturers as top companies in India
with a total turnover of US$ 3 bn. These companies are in the process of making a mark on
the global arena, and some have already acquired assets abroad.
Industry Structure
The total turnover of the Indian auto component industry is estimated at US$9 bn in 2006.
The industry has the resources to manufacture the entire range of auto products required
for vehicle manufacturing, approximately 20,000 components. The entry of global
manufacturers into India during the 1990s enabled induction of new technologies, new
products, improved quality and better efficiencies in operations. This in turn effectively
acted as a catalyst to the local development of the component industry.
The Indian auto component industry is extensive and highly fragmented. Estimates by the
Department of Heavy Industries, Government of India, indicate there are over 400 large
firms who are part of the organised sector and cater largely to the Original Equipment
Manufacturers (OEMs). Another 10,000 firms exist in the unorganised sector that operates
in a tier‐format. The firms in this segment operate in low technology products and cater to
Tier I and Tier II suppliers and also serve the replacement market
Around 4% of the companies operating in the auto component segment cater to 80% of
the demand emanating from OEMs. Within the unorganised segment, apart from supplying
in the aftermarket, a number of players are also involved in job work and contract
manufacturing.
Source: ACMA
The range of products manufactured, with each broad product segment having a different
market structure and technology, has negated any possible concentration of the market in
a few hands. The market is so large and diverse that a large number of players can be
absorbed to accommodate buyer needs. However, there are a select few large companies
that have integrated their operations across the value chain. The key to competing in this
industry is through specialisation by product‐type, and integrating operations across the
related area of specialisation.
An interesting insight provided by a study conducted by the National Council of Applied
Economic Research revealed that the market segments for auto components included
OEMs constituting 33%, local components having 25% with the balance 42% comprising
of spurious market including re‐conditioned parts. A large part of the spurious or grey
market companies are in the unorganised sector.
The regional base of auto component manufacturers is mostly concentrated in the West,
North and South of India.This regional concentration of auto component manufacturers
has been dictated by the emergence of automobile manufacturers in these regions. The set
up of Tata Motors, Bajaj, Mahindra & Mahindra and TVS in the 1950s and 1960s laid the
foundation for auto component manufacturers in the West and South, whilst the entry of
Maruti during the 1980s created the base in the North.
Industry Growth
Production of auto ancillaries was estimated at US$10 bn in 2005‐06 and has been
growing at a robust 20% per annum since 2000. Exports of auto components have been
strong growing at 24% per annum since 2000. This growth in exports if sustained for
another five years will see India’s auto components exports will touch US$ 5 bn by 2011
from the US$ 2 bn at present.
Till the 1990s, the auto component industry was solely dependent on the domestic
automobile industry to drive the demand for ancillary products. This composition of the
market however is undergoing radical changes with global outsourcing gaining
momentum. In recent times, exports has emerged as a significant driver of growth, and the
demand emanating from global OEMs and Tier I manufacturers has opened new
opportunities for the auto component industry in India. At the same time, a bright outlook
for the domestic automobile industry also offers significant growth potential, given the fast
rising income levels with a rapidly growing middle and high income consumers.
Share of exports in total production has risen from 10% in 1997 to 18% in 2006. The
composition of exports in terms of the proportion of OEM and aftermarket has also
undergone a sweeping change since the past decade. The ratio of OEM to aftermarket has
changed from 35:65 in the 1990s to 75:25 in 2006. While exports have been booming,
there has been a sharp rise in imports of auto components as well, especially in the last
three years. From an import of US$ 250 mn in FY03, they have gone up to US$750 mn in
FY06. This is a healthy trend, indicative of rising domestic demand.
Investments
Since 2000, the auto component industry has recorded an investment level of Rs 18 bn and
has attracted US$ 530 mn in terms of foreign direct investment. Investments in the sector
have been growing at 14% per year. In 2005‐06, investments touched US$ 4.4 bn, and are
expected to grow significantly in future.
The Investment Commission has set a target of attracting foreign investment worth US$ 5
bn for the next five years to increase India’s share in the global auto components market
from the present 0.4% to 3‐4%. This is a sizeable target considering the meagre amount of
FDI currently coming into the industry. The changing perception of global auto makers is
however fast altering this scenario.
With less than 1% share in the global market, India has tremendous potential to emerge as
a supply base. Several global giants like Ford and Toyota have already set up base in India
to source auto components. Outsourcing is fast catching up with domestic OEMs as well,
with most Indian OEMs today sourcing nearly 70‐80% of their component requirements
from vendors.
This changing business scenario is leading to an inevitable outcome of consolidation
within the industry. The takeover of Kar Mobiles by Rane Engine and of Gero Auto by Uma
Precision are few instances. However, such mergers and takeovers will be few and far in
between in the auto component industry, unlike the churn out anticipated in other
emerging industries – the principal factor being the vastness of the market and the range
of products that need to be delivered.
Rather than domestic consolidation, the general trend at present is for the large auto
component manufacturers to establish a global presence. Top auto component
manufacturers have already set up base in the global markets, especially in Europe.
Overall, there have already been 16 acquisitions, with six made in 2005. The industry is
the third highest among the Indian industries after IT and Pharma, in acquiring overseas
assets. These acquisitions have largely been in Europe and the USA. This trend has been
possible as the auto ancillary industry in these countries have been collapsing, thus
making it affordable to acquire these companies. Nevertheless, this will provide a base for
Indian companies to access the European and American markets.
Indian auto component companies are also setting up bases in other emerging economies,
who are potential competitors, for instance, Sundaram Fasteners’ greenfield facility in
Zhejiang and Bharat Forge’s joint venture with the Chinese automotive major FAW
Corporation. Another auto component manufacturer with plans to enter China is PMP
Components, which intends to set up a sourcing base to establish itself as a low cost
supplier.
These trends are indicative of the changing business environment in the country. Top auto
component manufacturers are gearing to take big risks. Their cross‐border vision has
established them as global companies. Though the going‐global phenomenon is limited to a
handful of companies, the smaller companies are also indirectly gearing to this trend by
entering into formal manufacturing contracts and specialisation.
Prospects
Looking forward, the industry displays tremendous potential in generating employment
and boosting entrepreneurship in the country. The spate of new investment plans
announced by global and domestic automobile manufacturers promises the emergence of
India as a global hub for auto components.
The industry is transforming, and the boost in demand will see the emergence of several
new players in the industry. The vast market for auto components, and the diverse
products and technology involved ensures a place and role for many. At the same time, the
entry of several global automobile manufacturers will bring in more regulation into the
industry and see a pruning of the spurious market. Among the smaller players in the
unorganised segment, this implies moving away from being standalone companies, to
entering into either contract manufacturing or being ancillary units. The newly defined
rules are specialisation, development and delivery that hold the key to success in the auto
component industry.
Foreign Acquisitions by Indian Companies
Federal Forge USA
Imatra Kilsta AB Sweden
Scottish
Scotland
Stampings Ltd
Motherson Sumi
WOCO Group Germany
G&S
Kunststofftechnik Germany
GmBH
Amtek Auto GWK UK
New Smith Jones
USA
Inc
Zelter Germany
Sundaram Fasteners Bleisthal
Produktions Germany
GmBH
Cramlington
UK
Forge
CDP GmBH Germany
EL Forge
Shakespeare
UK
Forgings
TVS Autolec
RBI Autoparts
Malaysia
SND BHD
Sona Koyo
Fuji Autotech France
SME’S IN THE AUTO COMPONENT INDUSTRY
The division of production processes and outsourcing among global automobile
manufacturers has led to a major reorganisation of the supply base within the automobile
and auto component industry. This new business model being followed by global
companies holds tremendous potential for the growth of small and medium enterprises
(SMEs) in India.
Defining SMEs
A well‐debated issue, the definition of small and medium enterprises in India was very
recently ratified. The Micro, Small and Medium Enterprises Bill, 2006, which is likely to
take effect from October 2006, define the segment on the basis of investments in plant and
machinery. Small enterprises are those with an investment of not more than Rs 50 mn in
plant and machinery, and medium enterprises with an investment of over Rs 50 mn but
less than Rs 100 mn in plant and machinery. This definition has finally put the segment
within a legal framework.
The traditional small scale industries have been in focus since Independence. The medium
enterprises are recent entrants, and part of government’s policy focus lately. The small
scale segment is a manifestation of India’s socio‐economic development model and has
met with the country’s long‐term expectations in terms of contribution to GDP, industrial
base, employment and exports. This segment forms a major part of India’s industrial base.
Recognising the importance of SMEs in the industrial development of the country, the
Government has initiated a range of programmes in diverse areas, viz. financing,
technology, innovation, market information, technical training and developmental
assistance. These initiatives are important in facilitating the growth of the SMEs. But it will
be the internal dynamics of industries, and the path India’s industrial development takes,
that will give a thrust to the emergence of SMEs. The auto component industry is one such
sector that would give a major boost to SMEs.
SMEs in Auto Components
Auto component SMEs are one of the fastest growing within the SME category of
industries. These units are key contributors to the total production of auto components
and also have a significant share in the exports of the industry.
As part of a highly fragmented industry, these companies mostly are part of the
unorganised sector. They operate in a tier framework, and most of the companies in the
SME segment are in the Tier II or below. Few of the suppliers to OEMs are medium scale
enterprises.
The SMEs are riding a boom phase, driven by demand from global auto manufacturers.
The industry is undergoing a major restructuring and many existing companies are
expected to move up in the value chain to a higher tier. Nevertheless, sustenance and
survival still remains an issue of concern for these companies as they will have to absorb
global best practices in this competitive environment.
Cost competitiveness, customer orientation, lead time, are some key factors the auto
component SMEs will have to imbibe to survive in the new global set‐up. At the same time,
these companies face the limitations of being SMEs, like
Low capital base
Limited generation of surplus funds for re‐investment due to tight working capital
cycle
Lack of awareness of business opportunities
Inadequate exposure to international environment
Limited geographical diversity of markets
Obsolete Technology
Poor infrastructure facilities
Despite these limitations, the SMEs have managed to significantly contribute towards
development of India’s industrial base. The key risks that the auto component SMEs faces
include:
Fluctuations in the cost of production; especially raw materials like steel,
aluminium, polymers
Poor negotiation powers due to fragmented nature of industry; which in turn limits
their pricing power
Dependence on traders and agents to access overseas markets which threatens their
competitiveness
Product substitutes due to fast‐changing technology
Addressing these challenges and risks will be crucial to promoting SMEs in the auto
component industry. The government has initiated cluster‐based development –
geographical concentration of enterprises having similar lines of business – which gives
rise to external economies and favours emergence of specialised technical, administrative
and financial services. This form of networking of small firms is a means of achieving
economies of scale. Extending this intitiative further, the government is encouraging banks
to adopt a cluster‐based lending approach to ease availability of funds to SMEs.
Multinational automobile manufacturers like Magna International of Canada, Delphi and
Ford of US and some European companies have announced plans to enter the Indian
markets. This bodes well for the auto component industry as it would enable the collective
development auto component SMEs. This will bring in better technology, skills, new
products and an assured market. Strategic tie‐ups and contract manufacturing is another
way forward for SMEs in the auto component industry.
Looking forward, it is the best of times for Indian auto component manufacturers. The
outlook for the industry is bright and is expected to continue on a high‐growth trajectory
for the next 10 years. Capitalising on this growth prospect will mean keeping pace with
global developments and imbibing capabilities that will give an edge to Indian SMEs in
surviving this rapidly changing competitive environment.
Auto Component Clusters in India
State No.
Andhra Pradesh 1
Delhi 1
Gujarat 5
Haryana 3
Jharkhand 1
Karnataka 2
Maharashtra 5
Madhya Pradesh 1
Punjab 4
Tamil Nadu 1
FUTURE OUTLOOK
Current trends indicate a smooth run for the auto component industry. In fact, since 2000,
this is one sector which has made a global mark and has been identified as a sunrise
industry. The industry is transforming from being highly domestic‐centric, to a force ready
to face global competition.
The factors that will drive growth for the auto component industry are:
The growth expected in the domestic automobile industry will give a fillip to the
auto component sector. The Indian automobile industry offers great potential
considering the low penetration along with rising income levels and a rapidly
growing middle class. These factors will see a boost in demand for vehicles,
especially passenger cars and two wheelers. These two segments are estimated to
grow at between 10‐12% for at least the next five years.
The entry of global OEMs, making India as their manufacturing base, has given a big
boost to the industry. For instance, Skoda plans to source parts for its European
operations from its Indian base and raise indigenisation level for Indian models to
70%. This trend has also enabled Indian companies to gain a competitive edge in
the global market. Further, the model of cluster‐based development prominent in
this sector will provide economies of scale.
Export of automobiles has also emerged as a key component of growth. Rising
exports of Indian‐made vehicles like M&M’s Scorpio model, Bajaj Auto’s Bikes, Tata
Motors’ City Rover are indirectly increasing the demand for Indian auto
components. Also, the export of India‐made models of global OEMs like Hyundai’s
Santro Xing and Suzuki’s Alto has given a boost to the industry.
De‐regulation and the Government’s policy initiatives have facilitated growth and
focus has now shifted towards attracting foreign direct investments. Also, the
Government’s initiative towards road development will give a boost to demand for
vehicles and indirectly auto components.
The Government’s initiatives towards opening up channels of finance.
Investments coming in for research and development will keep the industry abreast
of the latest technology.
Entry of global OEMs has transformed the Indian automobile and auto components
landscape. India is being perceived as a major market for cars and two wheelers by global
OEMs. Before the end of 2006, at least 30 new car models are expected to be launched by
foreign OEMs.
These factors portend a robust auto ancillary industry in India and the overall expected
good growth will provide several opportunities for the emergence of new enterprises.
Extending their reach to global markets is the pre‐dominant outlook among the top auto
component manufacturers in the country. The vision to compete globally comes from the
inherent strengths the Indian auto component industry possesses. Some features are:
Cost reduction of 25‐30% in production in the domestic market compared to
overseas
Low labour costs
Designing, engineering and technical skills
Established quality systems
Availability of raw materials
Adaptability to new technology
Investments in research and development, coming in from global OEMs. This stands
out positively in favour of India. Key players are not only willing to invest in R&D
but also in mechanical and engineering operations. These investments are expected
to increase in the near future
Though India rides on these inherent strengths, a few risks exist that the auto component
manufacturers may have to confront.
A global slowdown can derail the prospects of the industry.
Volatility in the prices of metals and other inputs could erode the industry’s cost
competitiveness. Further, global OEMs expect a commitment of 5‐10% reduction in
prices every year.
Tier I manufacturers taking up greenfield projects overseas.
Intense competition from counterparts in other emerging economies may add
pressure on margins of manufacturers.
The Indian auto component industry is poised for robust growth till 2010. There is a
perceptive exuberance in the industry and growth estimates indicate a booming industry.
Going by current trends in production and exports of auto components, indicate a
doubling of the domestic auto component industry by 2010. The production of auto
components could grow to US$22 bn by 2010. Similarly, India’s exports of auto
components could grow to US$4.5 bn as compared to US$1.8 bn in 2005. Expected growth
in production and exports of auto components is shown in the graphs below.
This growth outlook implies opportunities for the small and medium enterprises. The
overall trend is encouraging, but remaining competitive in this changing scenario will be
the toughest challenge. The combination of low manufacturing costs along with quality
systems would give an edge to companies in terms of pricing and quality. Expansion and
diversification will help break into new markets. It would be imperative for these
companies, which are largely based on traditional management practices, to imbibe
technology in a big way. The SMEs can exploit these opportunities through joint ventures,
collaboration and technical tie ups. Knowledge, specialisation, innovation and networking
will determine the success of the SMEs in this globally competitive environment.
Source: www.dnb.co.in