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MARKET ATTRACTIVENESS OF AUTO
             COMPONENT BUSINESS IN INDIA




Prepared For:




Prepared By:                ,
                                                                  January 2009
               IMRB International
       INVESTMENT POTENTIAL IN AUTO COMPONENT INDUSTRY IN INDIA           1
Preface
Thai-Indian business relations have improved considerably over the past decade.
Thailand and India are close to concluding a Free Trade Agreement (FTA) covering trade
in goods by 2010. The Free Trade Agreement between Thailand and India is expected to
improve trade relations between the two countries further. The FTA covering trade in
goods would lead to long term mutual benefits in trade and investment and the
partnership would be expanded further to cover technology know-how and expertise.

India's primary imports from Thailand are machinery, electronic appliances, textiles,
plastic material, transport equipment, vegetable oil and latex. The major items of imports
under FTA are polycarbonate, cathode-ray tubes, color-TVs, air conditioners and
Aluminum products. Thailand’s main imports from India are jewelry, gemstones, steel,
pharmaceuticals and ferrous metal ores.

India's trade with Thailand could touch USD 7 billion by 2010-11 propelled by a
doubling in transaction under Free Trade Agreement (FTA). The EHS was implemented
on September 1, 2004, under which tariffs on 82 items were to be phased out by
September 1, 2006 by both the sides.

The trade between Thailand and India is estimated to be US $ 7 billion by 2010-11 from
US $ 2.2 billion in 2005-06.

The total trade of 82 items under Early Harvest Scheme (EHS) of the FTA was increased
by over 140 percent to about US $ 358.63 million in 2005-06 from US $ 149 million in
2003-04. The share of these 82 items in India-Thailand trade increased from 10.34
percent in 2003-04 to 15.68 percent in 2005-06.

Thailand’s export to India of the identified 82 EHS items was increased from US $ 84.64
million to US $ 275 million during the period from 2003 – 04 to 2005 – 06. During the
same time, India’s export to Thailand of these items increased from US $ 64.28 million to
US $ 83.03 million during the same period.




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                 2
In 2007, Thailand’s export for these 82 items was US $ 406.31 million. Due the FTA
between two countries, Thailand is able to manage the trade surplus of US $ 598 in 2007
in bilateral trade between Thailand and India.

With significant potential for growth of business between the two countries, the Ministry
of Commerce, Thailand and Royal Thai Embassy would like to understand the
investment potential across the following identified product categories:-

       1. Home Utility and Furnishing: This would broadly include three product
           categories:-

               a. Furniture – Largely focusing on house hold furniture e.g. Sofa-set,
                   Dining table, Corner / corner table etc. Also covering office furniture
                   e.g. office chairs, cubicles, tables etc and open-air furniture i.e. the
                   furniture used in the garden, near pools etc.

               b. Interior Decoration items – This would include: Show pieces,
                   Wooden handicraft, photo frames, artificial flowers.

               c. Utensils – Household (kitchen), HoReCa (Hotel Restaurant Catering)
                   Segment, Institutional / Office.

               d. Plastic Products - Food containers, plastic storage boxes etc e.g.
                   Cello, Tupperware, Milton, Nyasa etc.

       2. Construction      Material:     This    would     include   Bathroom     Fittings,
           Tiles/Floorings (including wooden), Roof Tiles (used in the costal areas),
           Metal (Al, Tin etc) / Gypsum boards used for partition.

       3. Hospitality Services: This would be understood with the objective of tie-up
           with existing hotels – spas, specialty restaurant (e.g. Thai cuisine restaurant),
           health wellness services etc. The client would be interested in management
           control and running the property. The stand alone spas e.g. Kaya clinic is also
           covered in the purview of the study.




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                   3
4. Auto parts and accessories: It would cover both types of auto parts:-

              a. Essential auto parts (low volume high value items e.g. gear box,
                  clutch plates etc and high volume low value items like break pads etc).
                  These parts would be for 2-wheelers (e.g. moulding etc) and 4-
                  wheelers – both cars and commercial vehicles.

              b. Accessories / decorative items e.g. music systems, alloy wheels etc

In order to understand the trade potential across the above categories, the Ministry of
Commerce, Thailand and Royal Thai Embassy has commissioned Business and Industrial
Research Division (BIRD) of IMRB International to avail its research based consultancy
services




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                4
Table of Contents
1     EXECUTIVE SUMMARY ................................................................................................... 7
1.1   Automotive Component OEM and Replacement Markets .................................................... 10
1.2   Foreign Direct Investment and Government Policy .............................................................. 11
1.3   Attractiveness of Auto Component Sub-segments and Entry Strategy ................................. 11

2     GLOBAL AUTO COMPONENT INDUSTRY ................................................................ 13
2.1   Global Trends in the Automotive Industry............................................................................ 13
2.2   Major Auto and Auto Component Markets ........................................................................... 14
2.3   Major Auto Component Companies...................................................................................... 17

3     INDIAN AUTO COMPONENT INDUSTRY ................................................................... 18
3.1   Major Auto Component hubs in India ................................................................................... 19
3.2   Transition of Indian Auto Component Industry .................................................................... 20
3.3   Auto Component Industry Cost Buildup ............................................................................... 21
3.4   Classification of Auto Component Market ........................................................................... 22
3.5   Tier Structure of Auto Component Market ........................................................................... 23
3.6   Classification of Auto Components ...................................................................................... 24
3.7   Major Automobile Players .................................................................................................... 25
3.8   Major Automobile Component Players (Two, Three and Four Wheeler players) ................ 26
3.9   Foreign Collaboration in the Auto Component Industry....................................................... 27

4 INDUSTRY AND MARKET ANALYSIS ........................................................................ 29
4.1 Macro and Micro Environment Analysis: Indian Auto Component Market ......................... 30
4.2 SWOT Analysis: Indian Auto Component Market ............................................................... 31

5 MARKET SIZE AND GROWTH FORECASTS............................................................. 33
5.1 Global auto component market size and growth estimates ................................................... 33
5.2 Indian auto component market size and growth estimates .................................................... 34
    5.2.1    Production (in Number) and Growth rates of all vehicle categories
    including two wheelers .............................................................................................. 34
    5.2.2    Consolidated Production, Export and Investment in value terms ............... 35
    5.2.3    Value wise break up of sub-segments – two and four wheelers ................. 36
    5.2.4    Import estimates and trends (for 2 and 4 wheelers) .................................... 36
    5.2.5    Auto Component Export Destinations ........................................................ 38
    5.2.6    Trends in growth and margins – Two and Four wheelers .......................... 39

6     AUTO COMPONENT OEM AND REPLACEMENT MARKET ................................. 40
6.1   OEM Market in the Indian auto component industry............................................................ 40
6.2   OEM Component Sourcing ................................................................................................... 40
6.3   OEM Vendor Selection Process ............................................................................................ 41
6.4   Inventory in Supply Chain of OEM suppliers ....................................................................... 42
      6.4.1   Small and Medium OEM vendors .............................................................. 42
      6.4.2   Large OEM vendors / strategic Tier-1 suppliers......................................... 43



MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                   5
6.5   Break up of replacement parts market by type of vehicle ..................................................... 44
6.6   Automotive component replacement market: impact of structural changes ......................... 44
6.7   OEMs’ focus on replacement market .................................................................................... 45
6.8   Channel structure for auto component market ...................................................................... 46

7     GOVERNMENT INITIATIVES........................................................................................ 48
7.1   Foreign Direct Investment ..................................................................................................... 48
7.2   Auto Policy ............................................................................................................................ 48
7.3   Automotive Mission Plan 2016 ............................................................................................. 50

8     GROWTH DRIVERS AND CHALLENGES ................................................................... 51
8.1   Growth Drivers for Replacement Demand ............................................................................ 52
8.2   Issues and Challenges – Indian Auto Component Industry .................................................. 53
8.3   Indian Auto Component Industry amid changing global scenario ........................................ 54
8.4   Critical Success Factors......................................................................................................... 55

9     CONSUMER PREFERENCES FOR AUTO COMPONENTS ...................................... 56

10 ATTRACTIVENESS OF AUTO COMPONENT SEGMENTS FOR THAI
INVESTORS ............................................................................................................................... 58
10.1 Attractive segments within auto component market for Thai investors ................................ 58
10.2 Business Models for Collaboration ....................................................................................... 61

11 CONCLUSIONS AND RECOMMENDATIONS ............................................................ 63
11.1 Entry Strategy for Thai Investors in the Indian Auto Component Business ......................... 63
11.2 Recommended Distribution Channel for Thai investors ....................................................... 65

12 ANNEXURE: AUTO POLICY .......................................................................................... 67

13 LIST OF EXHIBITS ........................................................................................................... 77

14 REFERENCES .................................................................................................................... 79




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                             6
1 EXECUTIVE SUMMARY
The Indian automobile ancillary sector is transforming itself from a low-volume, highly
fragmented one into a competitive industry and backed by competitive strengths,
technology and evolving value chain. The Indian Auto component industry has
transitioned from a supplier for the global aftermarket to becoming a full-scale global
Tier 1 supplier.

The components in the Indian automotive component market are classified into Engine
parts, Drive transmission and steering parts, Body and chassis parts, Suspension and
braking parts, Electrical parts and Equipment and other parts.

The macro environment of the Indian auto component industry can be assessed by
understanding the social / consumer shifts, understanding its political and legal
environment, technological environment and economic shifts. This 9-forces analysis for
Indian auto component industry is done in the exhibit below:




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                              7
Market Analysis – Indian Auto Component Market

                                                                                                                                              Technological shifts
               Political / Legal Environment
                                                                                                                                  - Fast becoming global hub for R&D: GM, Daimler
  - FDI growing due to competitive advantage; witnessed
                                                                                   Entry Barriers                              Chrysler, Bosch, Suzuki, Johnson Controls etc. have set
 CAGR of 21.7% during 2002 – 07. The FDI was USD 7.2
                                                                      - OEMs’ “inclusive growth” ensuring long term                         up development centres in India.
                     Billion in 2007 – 08
                                                                    relationship especially for high value-adding items       - Casting and forging processes in India 25 to 30 % lower
  - Investment Commission of India facilitating FDI in all
                                                                 - Foreign suppliers supplying to global auto majors with                      than western counterparts.
                             forms
                                                                   local knowledge and expertise may have easy access           - 5 Indian auto component companies received coveted
          - No repatriation issues after paying taxes
                                                                                                                                      Deming Prize, largest number outside Japan.




              Supplier Power                                                  Industry Competitors                                                   Consumer Power
                                                                          - 450 – 500 mid to large players with
       - Tier structure supporting vendor                                                                                                    - Auto OEMs have average 2 suppliers
                                                                         around 6000 – 7000 units in addition to
                   relationship                                                                                                                     to ensure competitiveness
                                                                           around 10,000 units in unorganized
    - Most Tier – 3 suppliers are small units                                                                                                  - New auto clusters being developed
                                                                                         segment.
       largely from unorganized segment                                                                                                          with OEMs and major ancillaries
                                                                        - Technical tie ups and R&D ensuring at
                                                                                                                                                                -
                                                                          least 2 major players across segments




                                                                                                                                             Economic shifts
                  Social / Consumer shifts                                      Threat of Substitutes                       - Concentration of disposable income in top 6 – 8 cities
- Auto component industry – incubator to entrepreneurship            - Less threat to substitute for organized players        - Rising spending patterns on “pampering” therapies
  initiatives especially for less value adding components            working with OEMs and emphasizing on R&D                - International economic environment augurs cautious
- OEMs developing and launching “India centric” vehicles                              for future needs                                             approach
      after understanding Indian consumers’ demands                   - Unorganized units stand chances for greater
                                                                                            threat


                                                        Exhibit: 18-Force Market Analysis of Indian auto component market




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                                                                                   8
According to Automotive Component Manufacturers’ Association (ACMA), the
production of automotive component in India was US$ 18 billion. It is growing at CAGR
of 27% since 2002-03. The exhibit below shows that Indian auto component industry is
growing more than 25% since 2003 – 04. The exports in 2007 – 08 were US $ 3.6 billion,
out of these close to US $ 1 billion auto components were exported to top-3 US
automotive majors i.e. GM, Ford and Chrysler.




                                      Indian Automotive Component Market


                                              Auto Component Production
                      20,000                                                                                                       18,000
                      18,000
                                                                                                                          15,000
                      16,000
   (In USD Million)




                      14,000                                                                                     12,000
                      12,000
                      10,000                                                                            8,700
                                                                                                6,730                              7,200
                       8,000
                                                                      5,430                   5,400
                       6,000                        3,894 3,965 4,470             3,750
                                                                                        4,400
                                                                                                    3,615
                                  3,278 3,008 3,249                         3,100
                       4,000                                    2,300 2,645             2,469 2,873
                                                                            1,274 1,692
                                                     456   625   578   760
                       2,000             330   350

                         -
                                                                                                                                *
                                  7

                                          8

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                                                                   -0

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                                                                                    -0

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                                                                                                                      -0

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                          96

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                                                               00

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                                                       -2




                                                                                                                           07
                         19

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                                                                                                                 20
                                                   99




                                                                                                                         20
                                                19




                                      Production                     Exports                    Investment
                           Exhibit 22: Market size and growth trends – Indian auto component market
                               Source: ACMA (Automotive Component Manufacturers Association)
                                                       * Estimated figures




The Indian auto industry and auto component industry in 2006 – 07 was US$ 34 billion
and US$ 15 billion. As per Government of India’s automotive mission plan 2016, the
Indian auto industry and auto component industry in 2015-16 is estimated to be US$ 105
billion and US$ 40 billion respectively. It signifies that auto component industry would


MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                                     9
grow more than two times in the next seven years. This high growth augurs the business
potential in the Indian automotive component industry in the long term.

The auto component industry is facing transient challenges due to the changing global
situation where 2 out of the top-3 U.S. are on the verge of filing bankruptcy. Since Indian
automotive component industry is exporting to these auto majors, the reduction in the
pace of growth is expected this year. This reduction is coupled with reduced growth rate
of domestic vehicles sales in 2008-09. These rough times, however, are short timed in the
light of Government’s automotive mission plan 2016 whereby it aims to achieve the turn
over of US$ 145 billion by 2016. The growth factors i.e. lesser penetration of vehicles,
growing income levels portends health growth for Indian auto and auto component
industry in the long term.

  1.1 Automotive Component OEM and Replacement Markets

The OEM (Original Equipment Manufacturer) market is also known as the organized
market segment in the Indian auto component industry. All the Tier-1 suppliers/ vendor
to OEMs have their respective distribution channels in the aftermarket (or replacement
market) segment.

The inventory in the value chain of Indian automotive industry varies according to the
size of auto component suppliers. The large strategic Tier-1 suppliers who are better
connected with OEMs through ERP (Enterprise Resource Planning) system are able to
manage inventories better. On the other size, the small and medium sized Indian auto
component players not leveraging technology end up piling inventories due to “bull whip
effect”.

The Indian automotive component replacement market have various channels selling
genuine and spurious parts that makes it one of the most dynamic market segment (out of
the three market segments i.e. replacement demand, OEM demand and export market).
According to the study conducted by IMRB International for SIAM in 2006-07, the
counterfeit components constitute about 35% - 51% of private vehicle components
replacement market. Lately, OEMs have started showing increasing interest in the
replacement auto component.


MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                 10
1.2 Foreign Direct Investment and Government Policy

The automatic approval for foreign equity investment upto 100 per cent of manufacture
of automobiles and component is permitted for the auto and auto component industry.
The import of technology /technological up gradation on the royalty payment of 5%
without any duration limit and lump sum payment of USD 2 million is also allowed
under automatic route in this sector. The norms for Foreign Investment and import of
technology have also been progressively liberalized over the years for manufacture of
vehicles including passenger cars in order to make this sector globally competitive. With
the gradual liberalization of the automobile sector since 1991, the number of
manufacturing facilities in India has grown progressively.

  1.3 Attractiveness of Auto Component Sub-segments and Entry
         Strategy
The exhibit below shows that the domestic market for high grade plastic, electronics /
Integrated Circuit auto parts would be best suited for the auto component imports from
Thailand. The other attractive sub-segments would be rubber based intensive parts and
skill intensive parts.


                         Attractiveness Matrix for Thai Investors

                                                                  Low                              High

                                                                    Relative Degree of Technical Expertise
                          Ability in cost effective supply




                High                                         - Rubber Intensive parts     High grade plastic, IC
                                                               e.g. tyres, Accessories    based electronic parts /
                                                               - Skill intensive parts          assemblies




                Low                                          High grade plastic, IC         Parts for evolving
                                                             based electronic parts /     technology aggregates
                                                                   assemblies




                         Exhibit 40: Attractiveness matrix for Thai investors



MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                              11
For business collaboration, we suggest that Thai investors should initially export these
products for OEMs and aftermarket in India. Later on, when the product volumes would
increase, we suggest that it should set up the assembly base in one of the auto clusters, to
be selected based on initial experience. The exhibit below pictorially represents the
attractive areas and the timeframe for entering across various auto component market
sub-segments in India.



                                                                Entry strategy for Thai Investors
                                                                                      Degree of Attractiveness

                                                                            Low              Medium                High

                                             Plastic, silicon intensive
               Auto Component Sub-segments




                                                 electronic parts

                                             Rubber intensive parts
                                                and accessories
                                                 Parts for evolving
                                               technology aggregates

                                                Skill intensive parts
                                               covering engine parts

                                              Labour intensive parts –
                                                casting, forging etc

                                                     Legend

                                                                Immediate entry as OEM & aftermarket supplier

                                                                Enter in these sub-segments after 1 – 2 years of
                                                                immediate entry
                                                                Do not enter


                                                   Exhibit 42: Entry strategy for Thai investors




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                   12
2 GLOBAL AUTO COMPONENT INDUSTRY
  2.1 Global Trends in the Automotive Industry

The world’s automotive manufacturing sector consists primarily of about 20 very
large multinational corporations. The automotive supply sector, however, comprises of
thousands of firms ranging in size from a few employees to more than 100,000.

According to industry estimates, the size of the global auto component industry in
the year 2008 was approximately US$1.4 trillion and is likely to grow to about
US$1.9 trillion by 2015. Out of this total auto component demand by 2015, about
40% (i.e. US$ 750 billion) is likely to be sourced from low cost countries (LCCs)
such as China, ASEAN countries and India. The trends that are shaping the global
automotive industry are shown in the exhibit below:-




                              Global Trends in the Automotive Industry


                                           Strategic “Tier-1" acting
                                        closely with OEMs for designs

                                                                                  Pressure to lower
   Level of profitability                                                         prices continues
          too low

                                            Global Trends –
                                          Automotive Industry

                                                                                    Continued
   Emerging markets are                                                            consolidation
  fastest growing markets
                                         Shared platforms & modules
                                           increasingly important


                            Exhibit 1: Global trends in the automotive industry




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                               13
2.2 Major Auto and Auto Component Markets

The United States is far ahead of other countries when it comes to vehicle population per
1,000 vehicle driving age. It is home to the largest passenger vehicle market of any
country In 2007, there were about 250 million vehicles in the United States.

The exhibit below shows the penetration of LCVs across the major countries and the
emerging economies like Brazil, China and India.




              Cars for 1,000 inhabitants in different countries




                       Exhibit 2: Penetration of LCVs in different countries
                                     Source: Secondary Search




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                               14
The exhibit below maps vehicle penetration and nominal GDP per capita. In the long run,
the emerging economies like India hold immense potential as far as global automobile
industry future is concerned.


     GDP / Capita vs. Vehicle Density: India vis-à-vis Major Markets




               Exhibit 3: GDP / Capita vs. Vehicle Density: India vis-à-vis major markets




The exhibit below shows per capita income and the number of inhabitants per vehicle in
the year 2002 and expected ratio and per capita income in the year 2014. After comparing
the potential for future auto and auto component markets, it can be deduced that the
emerging economies like China and India would be at growth stage whereas the
developed economies like US and Japan are the saturated stage, expected to remain
stagnant or grow at less rate in the medium to long term.


MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                     15
Vehicle Density vs GDP/per capita




              Exhibit 4: Vehicle density vs GDP / per capita – Current and Estimated in 2014
                           Source: EIU, Goldman Sachs and A.T. Kearney analysis

The above analysis clearly indicates the importance of U.S. automotive market for the
global auto component industries, especially from the emerging economies and ASEAN
countries. The exhibit below shows US Auto Component imports from the leading
exporters:-

                 Year             Mexico        Brazil      China       Thailand        India
                 2001              18,469        820         1,470          380           141
                 2002              20,433       1,137        1,885          516           177
                 2003              21,477       1,319        2,363          498           191
                 2004              23,672       1,550        3,246          540           296
                 2005              25,445       1,847        4,328          535           426
                   Exhibit 5: Major US Auto Component Imports (In US$m): 2001-05
                     Source: US Census Bureau’s Foreign Trade Statistics 2001-2005




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                         16
2.3 Major Auto Component Companies

The exhibit below shows top automotive component players and their sales figures
globally in 2004 and 2005. Robert Bosch Corporation (entered in India in collaboration
with MICO as MICO Bosch but now has standalone existence) and Delphi Automotive
Systems are the globally ranked number one and two respectively according to their sales
figures.


Company                                   Sales in 2004        Sales in 2005    Change%
                                           (USD Bn)             (USD Bn)
Robert Bosch Corporation                       35.4                 30.7         -13.28
Delphi Automotive Systems                      28.6                 26.9          -5.94
Denso Corporation                              23.2                  25            7.76
Magna International                            20.6                 22.8          10.68
Johnson Controls Inc.                          17.7                 19.2           8.47
Lear Corporation                               16.9                 17.1           1.18
Visteon Automotive Systems                     18.7                 16.9          -9.63
TRW International                               12                  12.6           5.00
Eaton Corporation                               9.8                 11.1          13.27
                  Exhibit 6: Top Ten Auto Component Manufacturers-2004 & 2005
                             Source: Various Auto reports, Database search




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                   17
3 INDIAN AUTO COMPONENT INDUSTRY
The Indian automobile ancillary sector is transforming itself from a low-volume, highly
fragmented one into a competitive industry, and backed by competitive strengths,
technology and transition up the value chain. Broadly the Indian automotive component
industry can be divided into the organized and the unorganized segments. While the forte
of the organized sector is the high valued added precision engineering products, the
presence of a large unorganized sector is characteristic especially of the lower value-
added segments of the industry.

The ACMA-McKinsey Vision 2015 document forecasts the potential for the Indian auto
component industry to be US$ 40-45 billion by 2015. Investments and exports in this
segment are witnessing continuous growth. Global automobile manufactures see India as
a manufacturing hub for auto components and are rapidly ramping up the value of
components they source from India due to:

• The cost competitiveness in terms of labor and raw material

• Its established manufacturing base

• Fine quality of components manufactured in India (used as original components for
   vehicles made by General Motors, Mercedes, IVECO and Daewoo among others).




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                              18
3.1 Major Auto Component hubs in India

In India, there are four major clusters as far as auto and auto components are concerned.
The Chennai cluster has around 25 – 30% organized auto component manufacturers. The
exhibit below maps major auto and auto component clusters in India:-


            Major Auto and Auto Component Cluster




  Delhi NCR and
  Pantnagar cluster



                            text




                text




 Pune cluster

                                          Chennai cluster
                          text


                                          Bengaluru cluster




                       Exhibit 7: Major auto and auto component clusters in India
                                        Source: Secondary search




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                               19
3.2 Transition of Indian Auto Component Industry

The Indian Auto component industry has transitioned from a supplier for the global
aftermarket to becoming a full-scale global Tier 1 supplier. The transition has been
brought upon by increased competition from foreign players that have helped Indian auto
component industry becoming auto component manufacturer and export of complex auto
spare parts. The exports from Indian auto components manufacturers to U.S. top 3
automotive majors have been in excess of US $ 900 Million last year. The exhibit below
shows the transition of Indian auto component industry.



                                    Transition of Indian Auto Component Industry

                               Rotating Auto                                        Heavy Forgings
                               Electricals                                          Wheel Rims
                               Tyres & Tubes
                      High
 Product Complexity




                                                        Small Castings &            Plastic Components
                                                        Forgings
                      Medium




                                                                        th
                                                                      Pa
                                                               iti on
                                                            ns
                                                        Tra
                               Hand Tools
                               Metal bonded &
                      Low




                               Moulded Rubber Parts



                                     Aftermarket              Tier 2-n supplier             Tier 1 supplier
                                                                                                         Customer complexity

                                               Exhibit 8: Transition of Indian auto component industry




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                        20
3.3 Auto Component Industry Cost Buildup

    Across the auto component industry, material cost is almost the half of the total cost build
    up of the total expenditure. The exhibit below shows the percentage break up of total cost
    in the auto component industry.

    Auto component industry cost item                                                           %
    Material Costs                                                                            50.9%
    Power & Fuel                                                                               4.4%
    Employee Costs                                                                             5.9%
    Other Mfg Expenses                                                                         4.1%
    Selling expenses                                                                           2.1%
    Interest & Finance Costs                                                                   1.5%
    Depreciation                                                                               3.3%
    Tax                                                                                        2.3%
    OPBDIT Margins                                                                            16.9%
    NPM Margins                                                                                8.6%
                               TOTAL                                                          100%
                          Exhibit 9: Auto component industry Cost Structure FY06
                                Source: Primary interviews and database search


    Out of the 5 sub-segments i.e. equipment parts, braking parts, steering parts, electrical
    parts and engine parts, the percentage contribution of raw material out of the total cost at
    75% is highest in the braking parts sub-segment. The exhibit below provides the cost
    break up for the auto component by segments in the Indian auto component market:-

                                      Equipment           Braking        Steering       Electrical    Engine
                                       Parts-%            Parts-%        Parts-%        Parts-%       Parts-%
Raw Material Cost                        60%                74%            71%            68%           51%
Power and Fuel Cost                       5%                 5%             6%             4%            4%
Employee Cost                            15%                 7%            10%            10%           21%
Consumable Stores                         1%                 3%             4%             2%            6%
Selling Cost                              5%                 3%             3%             1%            5%
Others                                   14%                 8%             6%            15%           13%
                  Exhibit 10: Segment-wise cost structure in the auto-component Sector FY06
                                 Source: Primary interviews and database search




    MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                            21
3.4 Classification of Auto Component Market

The auto component industry can be classified into the 3 channels; as far as auto
component market is concerned. The classification of auto component market, as per the
market spread, is shown in the exhibit below:


            Classification of Auto Component Market


                            Auto Component Market




     OEM demand                  After market demand                 Exports demand



                   Auto Components                         Auto Accessories

                       Exhibit 11: Classification of auto component market



The OEM (Domestic and Export demand) contributes to 70% of the turnover, rest 30% of
the auto component demand is generated through aftermarket or replacement demand.


                     Break up of OEM and Replacement Demand

                          30%




                                                                             70%

                            OEM Demand (Including Domestic & Exports)
                            Replacement Demand

                      Exhibit 12: Break up of OEM and replacement demand
                                          Source: ACMA




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                               22
3.5 Tier Structure of Auto Component Market

The auto industry globally is structured based on vendor-supplier relationship with 3 to 5
nodes in the value chain ending at OEM (Original Equipment Manufacturer), that are also
the automotive major. In general, the OEMs in India typically have 100 to 500 Tier-1
equipment suppliers. These vendors are further classified as per the auto component sub-
segments that has been explained in the next section of this report. The tier structure in
the automotive industry is shown in the exhibit below:-


                      Tier Structure in the Auto Component Industry

                                                                                                       2nd
                                                                                                       Tier          2nd
                                                                                         2nd                         Tier
                                   2nd                                                   Tier
       2nd                         Tier
       Tier
                                                                                                        1st
                      1st                                                                              Tier
                     Tier
                                                     Tier
                                                      0.5                                   2nd
                                                                   OEM                      Tier                     2nd
       2nd
       Tier                                                                                                          Tier
                                   2nd
                                   Tier
3rd           3rd
                                                                                        2nd
Tier          Tier                                                                      Tier                  2nd
                            3rd        3rd                                                                    Tier
                            Tier       Tier

                                                                                                 1st             2nd
                                                                                                Tier             Tier
                     Tier-3 supplier to Tier-2 as well as
                                                                                     2nd
                           Tier-1 supplier to OEM                                    Tier                2nd
                                                                                                         Tier


                                   Exhibit 13: Tier structure in the auto component industry




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                 23
3.6 Classification of Auto Components

The components in the Indian automotive component market are classified in the
following sub-segments:-


                             Segments within Auto Component Industry

                           Engine parts
                           - Requires high precision and high quality adherence
                           - These fall into three broad categories: Core engine parts, fuel delivery
                           system and others.
                           - Major parts include Pistons, piston rings, engine valves, fuel pumps etc

                           Drive transmission & steering parts
                           - Major sub-segments in this category include gears (tones), wheels/wheel
                           rims, steering gears and systems
                           - Major parts include starter motors, generators and spark plugs, gears, steering
                           gears and systems, wheel, clutch etc
                           - Technology intensive, top ten players account for about 80% of the total
                           segment size
                           - Size of replacement market for this segment is likely to increase esp. for
                           wheels


                           Body and chassis
                           - The chassis is the skeleton upon which all other components are positioned
  Auto Component
                           - The parts under this segment include underbody, closure, body side, doors,
      Industry
                           plastic-molded parts and exhaust systems etc

                           Suspension & braking parts
                           - Major sub-segments in this category are shock absorbers, leaf springs and
                           brake shoe assembly segments
                           - Gabriel India Ltd and Munjal Showa Ltd are the majors in
                           the shock absorber segment

                           Electrical parts
                           - New technology in cars and electric start two-wheelers are leading to the
                           growth of this segment
                           - Major parts include carburettors, starter motors, generators, bimetal bearings,
                           distributors, air conditioning unit etc

                           Equipment & Others
                           - Major equipment parts include headlights, dashboard instruments,
                           wiper motors and electric horns etc. Other components include sheet metal
                           components and plastic moulded parts

                      Exhibit 14: Segments within auto component industry




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                        24
3.7 Major Automobile Players
   The significant growth in the Indian automobile market as a result of growing income and
   purchase power has provided opportunities to all the global automobile players to set up
   their base in India in the last one decade. The setting up of new plants has provided
   cluster development of automobile and automotive component market in India.

   The exhibit below shows the major players in the Indian market who have manufacturing
   units in India:-

   Passenger Cars         Commercial Vehicles              Two-Wheelers               Three-Wheelers
Maruti Suzuki             Ashok Leyland                Hero Honda                  Bajaj Auto
Hyundai                   Tata Motors                  Bajaj Auto                  Piaggio
Tata Motors               Eicher Motors                TVS Motors                  Mahindra & Mahindra
Honda                     Swaraj Mazda                 Royal Enfield Motors        TVS Motors
Mahindra & Mahindra       Volvo                        Kinetic Motors              Tata Motors
Toyota                    MAN-Force                    Suzuki Motors               Force Motors
Fiat                                                   Yamaha Motors
Hindustan Motors                                       Honda
General Motors                                         LML India
Ford
Volkswagen
Renault
Mercedes Benz
Skoda
BMW
Volvo
                Exhibit 15: Auto Component Sub Segments and Major Players in Indian Markets




   MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                        25
3.8 Major Automobile Component Players (Two, Three and Four
        Wheeler players)
There is not any distinction between the two wheeler and four wheeler automobile
component players in the Indian automobile component industry. The major organized
players who are catering to two wheeler OEMs are also catering to four wheeler OEMs.
However, for some niche commercial vehicle components, due to specialized load
bearing and design requirements, some automobile component players are the vendors
only to commercial vehicles.

The exhibit below shows the major players operating in the key sub-segments in the
product segments of the auto components:-

    Product Segment                  Key Sub-Segments            Major Players
                               Gears & Drive                1. Rico Auto Inds
                               Clutches                     2. Automotive Axles
Transmission and Steering      Axles                        3. Wheels India Ltd.
                               Others                       Sona Koyo Steer.
                                                            GKN Driveline (India)
                               Starter Motors, Generator,   Denso
                               Distributor, Spark Plugs,    Motherson Sumi
                               Ignition Coil, Flywheel      MICO
Electrical Parts
                               Magnet, Voltage Regulator,   Minda Industries
                               Electrical Ignition          India Nippon
                                                            Lucas TVS
                                                            Escorts
                                                            India Pistons
                                                            Goetze (India)
                               Pistons
                                                            India Pistons
                               Piston Rings
                                                            Rane Engine Valves
Engine Parts                   Engine Valves
                                                            Shriram Pistons & Rings
                               Carburettors
                                                            Spaco Carburettors
                               Fuel Delivery System
                                                            Ucal Fuel
                                                            Lucas TVS
                                                            MICO Germany
                                                            Lumax, Autolite, Phoenix
                               Headlight
                                                            Lamps
                                                            Premiere Instruments &
Equipment                      Dashboard
                                                            Controls
                                                            Jay Bharat Maruti, Omax
                               Sheet Metal
                                                            Auto, JBM tools
                               Brake System                 Automotive Axles
Suspension and Braking
                               Brake Linings                Brakes India


MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                            26
Shock Absorbers                         Kalyani Brakes
                                                                        Allied Nippon
                                                                        Rane Brake Lining
                                                                        Sundaram Brake
                                                                        Gabriel India
                                                                        Munjal Showa
                                Fan Belts                               Rico Auto
Others
                                Sheet Metal                             Rico Auto
             Exhibit 16: Auto Component Sub Segments and Major Players in Indian Markets
                                        Source: Database search


   “Top 50 auto component companies in India would have around 1000 auto
  component units across clusters. The vendors supplying to OEMs can be considered
  as organized segment players. These (organized players) would be around 5,000 –
  6,000. The total players including unorganized segment would be around 15,000.”
                     - Sr. Vice President, One of the leading Tier-1 component suppliers



Since components used in Commercial Vehicles and Tractors call for the properties of
high strength and load requirement, it was, therefore, observed that the operation of these
parts manufacturers are following in nature:

   a) The manufacturer is a niche player exclusively catering to the need of
         Commercial Vehicle or Tractor replacement market segment OR

  b)     A large organized player supplying to the traditional 2& 3 wheeler and passenger
         vehicles component markets has established a separate SBU (Strategic Business
         Unit) for servicing the need of Commercial Vehicles and Tractors segment

 3.9 Foreign Collaboration in the Auto Component Industry
The Indian automotive industry is characterized by a strong competition between
increasingly quality conscious manufacturers. The large, highly skilled but low cost
manufacturing base makes partnering linkages with overseas players attractive. These
strengths coupled with India’s well established strengths in IT/software combined
together to make India an emerging player in this sector. However, the industry needs to
continue to increase its quality standards and develop new products to compete globally.
Many domestic manufacturers have successfully entered into strategic alliances/


MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                     27
collaborations while others are actively chalking out their plans. Many of the world’s
       leading Tier-1 suppliers have set up manufacturing facilities in India including Bosch,
       Delphi, Visteon and Denso etc. Additionally, there is a well-developed domestic
       component and ancillary industry with some suppliers already meeting global technical
       and quality standards at the Tier-1 level. Some of India’s leading OES (Original
       Equipment Suppliers) include TACO, Bharat Forge, Sundaram Clayton, and Sundaram
       Brake Linings that have proven quality track record. However, many other suppliers lack
       such competence and are looking to upgrade their process/technologies to remain
       competitive. The exhibit below shows a part of Indian auto companies that have
       collaborated with the foreign partners in the Indian market:-

                                                            Name of Foreign
          Name of Indian Company                                                           Item of Manufacture
                                                             Collaborators
Amtek Auto Ltd., Gurgaon                              Bendo Kogyo, Japan                   Fly wheel ring gears
Jay Bharat Maruti Ltd., Gurgaon                       Allied Signal, USA                   Seat belts and Air bags
Subros Ltd., New Delhi                                Allied Signal, USA                   Catalytic converters
                                                                                           Exhaust Systems,
Mark Exhaust Systems Ltd., Gurgaon                    Sankei Giken, In.Co., Japan
                                                                                           Catalytic Converters
                                                      Saint Gobain Vitgrage,               Laminated Safety Glass
Atul Glass Industries Ltd., New Delhi                 France
                                                      Alcan Deutschland GmbH,              Pistons & Piston Rings
Menon Pistons Ltd., Kholapur                          Germany
                                                      Rockwell International Corp.,        Axle systems
Automotive Axles Ltd., Mysore                         USA
                                                      Blue Chip Products Inc.,             Water pumps
Autolec Industries, Madras                            USA
Spicer India Ltd., New Delhi                          Dana Corp., USA                      Engine bearings
                                                                                           Ball joints & Suspension
Sona Steering Systems Ltd., New Delhi                 Somic Ishikawa, Japan
                                                                                           joints
                                                                                           Asbestos free brake
Sona Steering Systems Ltd., New Delhi                 Fedoro, UK
                                                                                           linings
Sona Steering Systems Ltd., New Delhi                 Matsuda Industries, Japan            Cold forging
Haryana Sheet Glass Ltd., Haryana                     Pilkington Plc., UK                  Laminated sheet glass
                                                      Johnson Controls Inc., USA           Seating systems
                                                      Sommer Allibert, France              Interiors and Plastics
                                                      Yazaki, Japan                        Wiring harness
                                                                                           Transmission of steering
Tata Industries Ltd., Bombay                          ZF, Germany
                                                                                           systems
                                                      NIFCO, Japan                         Plastic Fasteners
                                                                                           Brake systems, Electrical
                                                      ITT, USA
                                                                                           & wiper systems
                         Exhibit 17: Indian Auto Component-Foreign Collaborations (2006)
                                              Source: Database search




       MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                            28
4 INDUSTRY AND MARKET ANALYSIS
The macro environment of the Indian auto component industry can be assessed by
understanding the social / consumer shifts, understanding its political and legal
environment, technological environment and economic shifts. The micro environment of
the industry can be assessed under the Porter’s 5 forces framework by understanding the
entry barriers, threats and supplier / buyer power. Merging the two assessment
frameworks provides an indication of macros (at a broader level) and micro (at an
industry level) factors influencing the entry of new players in the market. This 9-forces
analysis on a framework (comprising macro and micro factors) for Indian auto
component industry is done in the exhibit below:-




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                               29
4.1 Macro and Micro Environment Analysis: Indian Auto Component Market

                                                        Market Analysis – Indian Auto Component Market

                                                                                                                                                 Technological shifts
               Political / Legal Environment
                                                                                                                                     - Fast becoming global hub for R&D: GM, Daimler
  - FDI growing due to competitive advantage; witnessed
                                                                                      Entry Barriers                              Chrysler, Bosch, Suzuki, Johnson Controls etc. have set
 CAGR of 21.7% during 2002 – 07. The FDI was USD 7.2
                                                                         - OEMs’ “inclusive growth” ensuring long term                         up development centres in India.
                     Billion in 2007 – 08
                                                                       relationship especially for high value-adding items       - Casting and forging processes in India 25 to 30 % lower
  - Investment Commission of India facilitating FDI in all
                                                                    - Foreign suppliers supplying to global auto majors with                      than western counterparts.
                             forms
                                                                      local knowledge and expertise may have easy access           - 5 Indian auto component companies received coveted
          - No repatriation issues after paying taxes
                                                                                                                                         Deming Prize, largest number outside Japan.




              Supplier Power                                                     Industry Competitors                                                   Consumer Power
                                                                             - 450 – 500 mid to large players with
       - Tier structure supporting vendor                                                                                                       - Auto OEMs have average 2 suppliers
                                                                            around 6000 – 7000 units in addition to
                   relationship                                                                                                                        to ensure competitiveness
                                                                              around 10,000 units in unorganized
    - Most Tier – 3 suppliers are small units                                                                                                     - New auto clusters being developed
                                                                                            segment.
       largely from unorganized segment                                                                                                             with OEMs and major ancillaries
                                                                           - Technical tie ups and R&D ensuring at
                                                                                                                                                                   -
                                                                             least 2 major players across segments




                                                                                                                                                Economic shifts
                  Social / Consumer shifts                                         Threat of Substitutes                       - Concentration of disposable income in top 6 – 8 cities
- Auto component industry – incubator to entrepreneurship               - Less threat to substitute for organized players        - Rising spending patterns on “pampering” therapies
  initiatives especially for less value adding components               working with OEMs and emphasizing on R&D                - International economic environment augurs cautious
- OEMs developing and launching “India centric” vehicles                                 for future needs                                             approach
      after understanding Indian consumers’ demands                      - Unorganized units stand chances for greater
                                                                                               threat


                                                             Exhibit 18: 9-Force Market Analysis of Indian auto component market




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                                                                                      30
The macro and micro environment can be analyzed by looking at Porter’s five forces for
micro environment analysis and PEST analysis for analyzing macro environment of the
auto component industry.

In the exhibit above, while looking at competitors, there are 450 – 500 medium to large
players with around 6000 – 7000 units in addition to around 10,000 units in the
unorganized segment. This distribution highlight that auto component industry is
dominated by unorganized players. It provides opportunity for organized Thai investors
to provide the products identified as their core competence in the later part of the report.
Analyzing other aspects like entry barriers, threat of substitute and supplier and consumer
power also helps in understanding the Indian auto component market and devising the
entry strategy and positioning plank for the products supplied by the entrepreneurs from
Thailand to Indian auto component market.




  4.2 SWOT Analysis: Indian Auto Component Market

The classical tool to assess the industry environment is through SWOT analysis. The
exhibit below identifies Strengths, Weaknesses, Opportunities and Threats (SWOT
analysis) in the Indian Auto Component Industry:-




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                  31
SWOT Analysis – Auto Component Industry


Strength                              KEY FEATURES                          Weakness
 ▪ Is globally cost competitive        ▪ Annual production turnover of      ▪ Industry has low level of research
 ▪ Adheres to strict quality          Rs. 210 billion (US $4.5 billion):    and development capability
                                      small by global standards
controls
                                       ▪ Around 5,000 players in the
                                                                             ▪ Industry is exposed to cyclical
 ▪ Has access to latest               unorganised sector and 400 in the     downturns in the automotive
technology                            organised sector.                     industry
 ▪ Provides support to critical        ▪ Share of unorganised sector at      ▪ Most component companies are
infrastructure and metal              23%: caters primarily to              dependent on global majors for
                                      replacement market
industries                                                                  technology
                                       ▪ Share of organised sector at
                                      77%: caters primarily to Original
                                      Equipment Manufacturers, exports
                                      and replacement market
                                       ▪ All prominent companies have
                                      technological tie-ups with global
                                      majors
                                       ▪ Manufactures products that may
                                      be classified into six categories:
                                      Engine Parts; Electrical Parts;
  Opportunities                       Drive, Transmission & Steering      Threats
  ▪ May serve as sourcing hub for
                                      Parts; Suspension & Braking Parts;  ▪ The presence of a large
                                      Equipment; and Others
  global automobile majors                                                counterfeit components market
                                       ▪ The fortunes of the industry are
   ▪ Significant export               largely driven by the automotive    poses a significant threat
  opportunities may be realised       industry                             ▪ Pressure on prices from
  through diversification of           ▪ Posted a decline in margins and  OEMs continues
  export basket
                                      returns in last five years till      ▪ Imports pose price based
                                      FY2002: working capital cycle
   ▪ Implementation of Value-                                             competition in the replacement
                                      increased during the same period
  Added-Tax (VAT) in FY2004                                               market
  will negate the cascading                                                ▪ Further marginalization of
  impact of prices                                                        smaller players likely
                          Exhibit 19: SWOT Analysis – Indian auto component industry



With the growing sales of automobiles, new global OEMs are entering in the Indian
automotive industry which in turn provides the auto component industry the opportunity
to register robust growth over next 5 – 8 years. The component industry has not more
than 50 players with turnover of more than US$ 500 million per annum. Around 70 –
80% of the total numbers of players, at the bottom of the pyramid, have revenues of less
than US$ 1 million per annum. The growing automobile demand and the increasing
awareness to purchase genuine spare parts in the aftermarket poses attractive market
opportunities for the two and four wheeler auto component manufacturers.




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                       32
5 MARKET SIZE AND GROWTH FORECASTS


  5.1 Global auto component market size and growth estimates

            Global Automotive Component Market (US$ billions)




                  Exhibit 20: Growth trends of global automotive component market
                                       Source: Database search



As shown in the exhibit above, the global automotive components consumption is
expected to grow from US$ 1.2 trillion in 2003 to US$ 1.65 trillion in 2015 (exhibit
below). As per one of the reports, of this US$ 1.65 trillion, LCC (Low Cost Country)
players can theoretically address roughly 42 per cent or US$ 700 billion. They cannot
address US$ 425 billion or 26 per cent of the market that will primarily be manufactured
by OEMs in their home countries. Another US$ 525 billion or 32 per cent of the global
market will be ruled out because of practical difficulties in off-shoring or because it will
yield negligible savings.




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                  33
5.2 Indian auto component market size and growth estimates

According to Automotive Component Manufacturers’ Association (ACMA), the
production of automotive component in India was US$ 18 billion. It is growing at CAGR
of 27% since 2002-03. The investment in the Indian auto component industry is also
gaining momentum with almost all major global automotive component manufacturers
are setting up their plants in India.

   5.2.1   Production (in Number) and Growth rates of all vehicle categories
           including two wheelers
The exhibit below indicates that in 2006-2007, out of the total automobiles market size of
around 1,10,65,000 vehicles, 94,42,000 or around 85% of the vehicles were two
wheelers. On an average, the overall annual growth rate of vehicles in the last 5 years has
been in excess of 15%.

        Category         2002-03      2003-04        2004-05                             2005-06   2006-07
 Passenger Car              609         843           1018                                1113       1323
 Utility Vehicle            114         146            192                                 197       222
 Commercial Vehicle         204         275            354                                 391       520
 Two-Wheeler               5076        5623           6530                                7609       9442
 Three-Wheeler              277         356            374                                 434       556
 Grand Total               6280        7244           8468                                9744      11065
 Growth Rate              18.13%      15.34%         16.90%                              15.06%    13.55%
 All Number in '000 units while Growth Rate is in percentage
 Source: Ministry of Heavy Industries, Government of India

                     Exhibit 21: Production and growth rates of all vehicle categories
                                             Source: ACMA
Above table also points out that the two-wheelers and passenger cars have been the most
significant product categories (combined share -97%) and growing steadily over the past
few years. The two wheeler replacement auto component market also holds significant
importance due to the sheer volumes. Therefore, the 2-wheeler automotive component
market cannot be ignored while gauging the attractiveness of automotive component
market of India. The synergies between the two-wheeler & four wheeler component
market also enable two-wheeler component manufacturers to service the four wheeler
segment easily.




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                             34
5.2.2                 Consolidated Production, Export and Investment in value terms
As per the exhibit below, the exports in 2007 – 08 were US $ 3.6 billion, out of these
close to US $ 1 billion auto components were exported to top-3 US automotive majors
i.e. GM, Ford and Chrysler.


                                      Indian Automotive Component Market


                                               Auto Component Production
                      20,000                                                                                                       18,000
                      18,000
                                                                                                                          15,000
                      16,000
   (In USD Million)




                      14,000                                                                                     12,000
                      12,000
                      10,000                                                                            8,700
                                                                                                6,730                              7,200
                       8,000
                                                                                       5,430                              5,400
                       6,000                                  3,894 3,965 4,470             3,750
                                                                                                  4,400
                                                                                                              3,615
                                  3,278 3,008 3,249                                   3,100
                       4,000                                              2,300 2,645             2,469 2,873
                                                                                      1,274 1,692
                                                               456   625   578   760
                       2,000                  330      350

                         -




                                                                                                                                  *
                                  7

                                          8

                                                   9




                                                                      1

                                                                              2

                                                                                       3

                                                                                               4

                                                                                                        5

                                                                                                                6

                                                                                                                         7
                                                         00




                                                                                                                                 8
                               -9

                                       -9

                                                -9




                                                                   -0

                                                                           -0

                                                                                    -0

                                                                                            -0

                                                                                                     -0

                                                                                                             -0

                                                                                                                      -0

                                                                                                                              -0
                                                          0
                          96

                                      97

                                              98




                                                               00

                                                                          01

                                                                                  02

                                                                                           03

                                                                                                   04

                                                                                                            05

                                                                                                                    06
                                                       -2




                                                                                                                           07
                         19

                                 19

                                           19




                                                              20

                                                                     20

                                                                               20

                                                                                       20

                                                                                                20

                                                                                                        20

                                                                                                                 20
                                                    99




                                                                                                                         20
                                                19




                                      Production                     Exports                    Investment
                           Exhibit 22: Market size and growth trends – Indian auto component market
                               Source: ACMA (Automotive Component Manufacturers’ Association)

As per the exhibit above the consolidated production of the two, three and four wheeler
auto component industry is growing at CAGR of 25 – 27% from the past 4 – 5 years. The
production is catering to both the domestic demand, coming from OEM and replacement
demand, and the growing rate of exports.

The investment in the auto component industry has also been doubled to USD 7.2 Billion
in the last three years. This highlights the growth momentum in the Indian auto
component industry.




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                                                     35
5.2.3   Value wise break up of sub-segments – two and four wheelers

The two wheeler automotive component market like the four wheeler automotive
component market can be classified into the same sub-segments categories. Out of the
consolidated automotive component market, the engine parts have the major share among
the other auto components. It accounts for 31% of the total auto component market (in
value terms). The equipments, electrical and other parts account for 10%, 12% and 7%
respectively of the total auto component market size (in value terms). The break up of the
auto component industry (in value terms including 2 and 4 wheeler components) is
shown in the pie chart below:


               Beakup of Various Segments in Indian Auto Component Industry
                                     (In Value terms)

                                        31%
                                                                           19%



                                 7%                                           12%
                                       9%
                                                10%               12%
                      Engine parts                        Drive transmission & steering parts
                      Body & chassis                      Suspension & braking parts
                      Equipment                           Electrical parts
                      Others
          Exhibit 23: Percentage breakup of sub-segments in the Indian auto component industry
                 Source: ACMA (Automotive Component Manufacturers Association of India)


  5.2.4   Import estimates and trends (for 2 and 4 wheelers)
The imports for the auto components are ranging 2-4% for the total replacement market
(which is 30% of total auto component demand in India). In the OEM demand, import of
auto-components is negligible (less than 1%), as it can be identified from the comment
below:-




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                          36
“All OEMs have their vendors located in India. However, some OEMs like us
     (Ashok Leyland) have set up their offices in China from where we are importing
     some components that are cost effective. These components would be less than 1% of
     the total auto component requirements
                    - Strategic Sourcing Official from one of leading Vehicle manufacturer



 Within imports of auto components, Engine and Suspension / Braking have relatively
 higher proportion in imports whereas Transmission and Equipments have lesser
 proportion.

 The table below highlights the items that are either high in import proportion (in value
 terms) or are growing at rapid rate i.e. 50% or more. India imported US$ 20 million auto
 components from China in 2004 – 05 whereas the imports from ASEAN countries were
 close to US$ 73 million during the same time. The estimated imports (based on the
 growth trends) from China and ASEAN countries in 2008 – 09 would be around US$ 120
 – 150 million and US$ 350 – 400 million respectively.

 Auto component import
                                Total Import – 2004-05 (US $ Million)             Growth Rate (2001-05)
 (OEM + Replacement)
                                          Imports     Imports     Share of               Imports    Imports from
                                 All                                           All
Components detail                          from        from       China &              from China     ASEAN
                               Imports                                       Imports
                                           China      ASEAN       ASEAN
Parts and accessory of motor
                                   543.38     3.98      61.16       12%      28%        28%           58%
vehicles
Engine parts                       203.19     8.99       3.09        6%      15%       113%           24%
Electrical parts and accessories    29.80     0.68       0.1         3%      26%        63%           -50%
Bumpers and parts                   23.09     0.23       1.59        8%      69%        74%           288%
Injection pumps, oil pumps,
                                    22.67     0.73       0.01        3%      39%       111%           -29%
water pumps
Drive axles with differential       18.63     0.01       0.87        5%      50%          -
Lighting equipment                  17.46      1.8       2.01       22%      24%        14%           107%
Other Brakes/Servo brakes           17.20      0.9       0.23        7%      46%        63%           -17%
Starter motors                      11.16      0.3       1.44       16%      33%       166%            5%
Clutches                             9.17      0.2       0.74       10%      25%        26%           147%
Wheels                               7.86     0.75       0.29       13%      80%       127%           14%
Steering wheels and columns          7.06     0.01       0.45        7%      45%        21%           208%
Rear view mirror                     4.23     0.74       0.6        32%      37%       104%           97%
Laminated safety glass               1.84     0.63       0.29       50%      87%       281%           313%
Total                               916.7     20.0       72.9                30%        55%           49%
                          Exhibit 24: Auto component imports (OEM + Replacement market)
   Source: ACMA (Automotive Component Manufacturers Association, DGFT (Directorate General of Foreign Trade)




 MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                                    37
The highlighted components above are the promising auto component products for both
two wheelers and four wheelers auto components that have are either high on value or the
rate of growth of import is significantly higher. These items could be looked as the
potential export items by Thai investors to export to India. The consumable items markets
like injection pumps, oil pumps, bumper and parts and wheels are growing at faster rate
in the replacement market due to increase vehicle population.
We expect the share of imported parts (especially from China and ASEAN countries
including Thailand) to grow in the future because of the two major reasons:-
    FTA’s that India has sign with a number of countries including Thailand would
       result in increase in imported parts
    Launch of similar products in India and China / ASEAN.


  5.2.5   Auto Component Export Destinations

The U.S. and European markets account for 28% each of the total exports from the Indian
auto component companies. The exhibit below shows the break up of the total auto
component export markets across the major auto importing markets.


                          Auto Component Export Destinations
                                  (In Value terms)
                                              28%




                                                                                27%
                           28%

                                             4% 2%              11%


                 U.S.       Europe         Asia        Africa       Australia         Others


                        Exhibit 25: Indian auto component export destinations
                                            Source: ACMA




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                        38
5.2.6   Trends in growth and margins – Two and Four wheelers
As mentioned in the section 5.2.2 above, the automobile market is growing at CAGR of
25 – 27%. Notwithstanding the temporary global economic meltdown, it is expected that
the domestic demand for automobiles would grow unabatedly over the next 3 – 5 years.

The exhibit below shows the gross margin and net margin at the distribution and retailer
level:-


                                 Gross Margins                                 Net Margins


    Distribution           Ranges between 12 – 15%                       Ranges between 4 – 6% based
    Margin                 based on type of part and                     on type of part and type of
                           type of manufacturer                          manufacturer



    Retail                 Ranges between 14 – 18%                       Ranges between 6 – 8% based
    Margin                 based on type of part and                     on type of part and type of
                           type of manufacturer                          manufacturer


                           Exhibit 26: Distributor and Retailer Margin



The average distribution margin per players (made by distributors / wholesalers) is
dependent on the number of layers in the channel. The margins and incentives play a key
role in pushing the product at the retail end. The margins are relatively higher for
electrical parts and brake & suspension parts.




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                                      39
6 AUTO COMPONENT OEM AND REPLACEMENT
    MARKET
This section highlights OEM supply chain and inventory management aspects for small
and large auto component supplier. In the replacement market segment, changes in the
replacement market including the increasing focus of OEM on aftermarket in the recent
years and the channel structure have been highlighted in this chapter.

  6.1 OEM Market in the Indian auto component industry

The OEM market is also known as the organized market segment in the Indian auto
component industry. All the Tier-1 automotive component vendors have their respective
distribution channels in the aftermarket segment. Typically, an OEM works with around
100 – 200 Tier-1 suppliers and around 500 Tier-3 / Tier-2 suppliers (to Tier-2 / Tier 1
suppliers), depending upon the diversity of product line offerings.

  6.2 OEM Component Sourcing
The automotive manufacturing industry in India is on par with the globally competitive
markets. All the plants are typically connected with ERP systems with their strategic
vendors and distribution channels that enable them to control raw material, WIP (Work In
Process) and finished products (vehicles) inventory. The exhibit below shows typical
order-to-delivery process supply chain in the automotive industry.




MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY                              40
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Report auto component_market

  • 1. MARKET ATTRACTIVENESS OF AUTO COMPONENT BUSINESS IN INDIA Prepared For: Prepared By: , January 2009 IMRB International INVESTMENT POTENTIAL IN AUTO COMPONENT INDUSTRY IN INDIA 1
  • 2. Preface Thai-Indian business relations have improved considerably over the past decade. Thailand and India are close to concluding a Free Trade Agreement (FTA) covering trade in goods by 2010. The Free Trade Agreement between Thailand and India is expected to improve trade relations between the two countries further. The FTA covering trade in goods would lead to long term mutual benefits in trade and investment and the partnership would be expanded further to cover technology know-how and expertise. India's primary imports from Thailand are machinery, electronic appliances, textiles, plastic material, transport equipment, vegetable oil and latex. The major items of imports under FTA are polycarbonate, cathode-ray tubes, color-TVs, air conditioners and Aluminum products. Thailand’s main imports from India are jewelry, gemstones, steel, pharmaceuticals and ferrous metal ores. India's trade with Thailand could touch USD 7 billion by 2010-11 propelled by a doubling in transaction under Free Trade Agreement (FTA). The EHS was implemented on September 1, 2004, under which tariffs on 82 items were to be phased out by September 1, 2006 by both the sides. The trade between Thailand and India is estimated to be US $ 7 billion by 2010-11 from US $ 2.2 billion in 2005-06. The total trade of 82 items under Early Harvest Scheme (EHS) of the FTA was increased by over 140 percent to about US $ 358.63 million in 2005-06 from US $ 149 million in 2003-04. The share of these 82 items in India-Thailand trade increased from 10.34 percent in 2003-04 to 15.68 percent in 2005-06. Thailand’s export to India of the identified 82 EHS items was increased from US $ 84.64 million to US $ 275 million during the period from 2003 – 04 to 2005 – 06. During the same time, India’s export to Thailand of these items increased from US $ 64.28 million to US $ 83.03 million during the same period. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 2
  • 3. In 2007, Thailand’s export for these 82 items was US $ 406.31 million. Due the FTA between two countries, Thailand is able to manage the trade surplus of US $ 598 in 2007 in bilateral trade between Thailand and India. With significant potential for growth of business between the two countries, the Ministry of Commerce, Thailand and Royal Thai Embassy would like to understand the investment potential across the following identified product categories:- 1. Home Utility and Furnishing: This would broadly include three product categories:- a. Furniture – Largely focusing on house hold furniture e.g. Sofa-set, Dining table, Corner / corner table etc. Also covering office furniture e.g. office chairs, cubicles, tables etc and open-air furniture i.e. the furniture used in the garden, near pools etc. b. Interior Decoration items – This would include: Show pieces, Wooden handicraft, photo frames, artificial flowers. c. Utensils – Household (kitchen), HoReCa (Hotel Restaurant Catering) Segment, Institutional / Office. d. Plastic Products - Food containers, plastic storage boxes etc e.g. Cello, Tupperware, Milton, Nyasa etc. 2. Construction Material: This would include Bathroom Fittings, Tiles/Floorings (including wooden), Roof Tiles (used in the costal areas), Metal (Al, Tin etc) / Gypsum boards used for partition. 3. Hospitality Services: This would be understood with the objective of tie-up with existing hotels – spas, specialty restaurant (e.g. Thai cuisine restaurant), health wellness services etc. The client would be interested in management control and running the property. The stand alone spas e.g. Kaya clinic is also covered in the purview of the study. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 3
  • 4. 4. Auto parts and accessories: It would cover both types of auto parts:- a. Essential auto parts (low volume high value items e.g. gear box, clutch plates etc and high volume low value items like break pads etc). These parts would be for 2-wheelers (e.g. moulding etc) and 4- wheelers – both cars and commercial vehicles. b. Accessories / decorative items e.g. music systems, alloy wheels etc In order to understand the trade potential across the above categories, the Ministry of Commerce, Thailand and Royal Thai Embassy has commissioned Business and Industrial Research Division (BIRD) of IMRB International to avail its research based consultancy services MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 4
  • 5. Table of Contents 1 EXECUTIVE SUMMARY ................................................................................................... 7 1.1 Automotive Component OEM and Replacement Markets .................................................... 10 1.2 Foreign Direct Investment and Government Policy .............................................................. 11 1.3 Attractiveness of Auto Component Sub-segments and Entry Strategy ................................. 11 2 GLOBAL AUTO COMPONENT INDUSTRY ................................................................ 13 2.1 Global Trends in the Automotive Industry............................................................................ 13 2.2 Major Auto and Auto Component Markets ........................................................................... 14 2.3 Major Auto Component Companies...................................................................................... 17 3 INDIAN AUTO COMPONENT INDUSTRY ................................................................... 18 3.1 Major Auto Component hubs in India ................................................................................... 19 3.2 Transition of Indian Auto Component Industry .................................................................... 20 3.3 Auto Component Industry Cost Buildup ............................................................................... 21 3.4 Classification of Auto Component Market ........................................................................... 22 3.5 Tier Structure of Auto Component Market ........................................................................... 23 3.6 Classification of Auto Components ...................................................................................... 24 3.7 Major Automobile Players .................................................................................................... 25 3.8 Major Automobile Component Players (Two, Three and Four Wheeler players) ................ 26 3.9 Foreign Collaboration in the Auto Component Industry....................................................... 27 4 INDUSTRY AND MARKET ANALYSIS ........................................................................ 29 4.1 Macro and Micro Environment Analysis: Indian Auto Component Market ......................... 30 4.2 SWOT Analysis: Indian Auto Component Market ............................................................... 31 5 MARKET SIZE AND GROWTH FORECASTS............................................................. 33 5.1 Global auto component market size and growth estimates ................................................... 33 5.2 Indian auto component market size and growth estimates .................................................... 34 5.2.1 Production (in Number) and Growth rates of all vehicle categories including two wheelers .............................................................................................. 34 5.2.2 Consolidated Production, Export and Investment in value terms ............... 35 5.2.3 Value wise break up of sub-segments – two and four wheelers ................. 36 5.2.4 Import estimates and trends (for 2 and 4 wheelers) .................................... 36 5.2.5 Auto Component Export Destinations ........................................................ 38 5.2.6 Trends in growth and margins – Two and Four wheelers .......................... 39 6 AUTO COMPONENT OEM AND REPLACEMENT MARKET ................................. 40 6.1 OEM Market in the Indian auto component industry............................................................ 40 6.2 OEM Component Sourcing ................................................................................................... 40 6.3 OEM Vendor Selection Process ............................................................................................ 41 6.4 Inventory in Supply Chain of OEM suppliers ....................................................................... 42 6.4.1 Small and Medium OEM vendors .............................................................. 42 6.4.2 Large OEM vendors / strategic Tier-1 suppliers......................................... 43 MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 5
  • 6. 6.5 Break up of replacement parts market by type of vehicle ..................................................... 44 6.6 Automotive component replacement market: impact of structural changes ......................... 44 6.7 OEMs’ focus on replacement market .................................................................................... 45 6.8 Channel structure for auto component market ...................................................................... 46 7 GOVERNMENT INITIATIVES........................................................................................ 48 7.1 Foreign Direct Investment ..................................................................................................... 48 7.2 Auto Policy ............................................................................................................................ 48 7.3 Automotive Mission Plan 2016 ............................................................................................. 50 8 GROWTH DRIVERS AND CHALLENGES ................................................................... 51 8.1 Growth Drivers for Replacement Demand ............................................................................ 52 8.2 Issues and Challenges – Indian Auto Component Industry .................................................. 53 8.3 Indian Auto Component Industry amid changing global scenario ........................................ 54 8.4 Critical Success Factors......................................................................................................... 55 9 CONSUMER PREFERENCES FOR AUTO COMPONENTS ...................................... 56 10 ATTRACTIVENESS OF AUTO COMPONENT SEGMENTS FOR THAI INVESTORS ............................................................................................................................... 58 10.1 Attractive segments within auto component market for Thai investors ................................ 58 10.2 Business Models for Collaboration ....................................................................................... 61 11 CONCLUSIONS AND RECOMMENDATIONS ............................................................ 63 11.1 Entry Strategy for Thai Investors in the Indian Auto Component Business ......................... 63 11.2 Recommended Distribution Channel for Thai investors ....................................................... 65 12 ANNEXURE: AUTO POLICY .......................................................................................... 67 13 LIST OF EXHIBITS ........................................................................................................... 77 14 REFERENCES .................................................................................................................... 79 MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 6
  • 7. 1 EXECUTIVE SUMMARY The Indian automobile ancillary sector is transforming itself from a low-volume, highly fragmented one into a competitive industry and backed by competitive strengths, technology and evolving value chain. The Indian Auto component industry has transitioned from a supplier for the global aftermarket to becoming a full-scale global Tier 1 supplier. The components in the Indian automotive component market are classified into Engine parts, Drive transmission and steering parts, Body and chassis parts, Suspension and braking parts, Electrical parts and Equipment and other parts. The macro environment of the Indian auto component industry can be assessed by understanding the social / consumer shifts, understanding its political and legal environment, technological environment and economic shifts. This 9-forces analysis for Indian auto component industry is done in the exhibit below: MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 7
  • 8. Market Analysis – Indian Auto Component Market Technological shifts Political / Legal Environment - Fast becoming global hub for R&D: GM, Daimler - FDI growing due to competitive advantage; witnessed Entry Barriers Chrysler, Bosch, Suzuki, Johnson Controls etc. have set CAGR of 21.7% during 2002 – 07. The FDI was USD 7.2 - OEMs’ “inclusive growth” ensuring long term up development centres in India. Billion in 2007 – 08 relationship especially for high value-adding items - Casting and forging processes in India 25 to 30 % lower - Investment Commission of India facilitating FDI in all - Foreign suppliers supplying to global auto majors with than western counterparts. forms local knowledge and expertise may have easy access - 5 Indian auto component companies received coveted - No repatriation issues after paying taxes Deming Prize, largest number outside Japan. Supplier Power Industry Competitors Consumer Power - 450 – 500 mid to large players with - Tier structure supporting vendor - Auto OEMs have average 2 suppliers around 6000 – 7000 units in addition to relationship to ensure competitiveness around 10,000 units in unorganized - Most Tier – 3 suppliers are small units - New auto clusters being developed segment. largely from unorganized segment with OEMs and major ancillaries - Technical tie ups and R&D ensuring at - least 2 major players across segments Economic shifts Social / Consumer shifts Threat of Substitutes - Concentration of disposable income in top 6 – 8 cities - Auto component industry – incubator to entrepreneurship - Less threat to substitute for organized players - Rising spending patterns on “pampering” therapies initiatives especially for less value adding components working with OEMs and emphasizing on R&D - International economic environment augurs cautious - OEMs developing and launching “India centric” vehicles for future needs approach after understanding Indian consumers’ demands - Unorganized units stand chances for greater threat Exhibit: 18-Force Market Analysis of Indian auto component market MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 8
  • 9. According to Automotive Component Manufacturers’ Association (ACMA), the production of automotive component in India was US$ 18 billion. It is growing at CAGR of 27% since 2002-03. The exhibit below shows that Indian auto component industry is growing more than 25% since 2003 – 04. The exports in 2007 – 08 were US $ 3.6 billion, out of these close to US $ 1 billion auto components were exported to top-3 US automotive majors i.e. GM, Ford and Chrysler. Indian Automotive Component Market Auto Component Production 20,000 18,000 18,000 15,000 16,000 (In USD Million) 14,000 12,000 12,000 10,000 8,700 6,730 7,200 8,000 5,430 5,400 6,000 3,894 3,965 4,470 3,750 4,400 3,615 3,278 3,008 3,249 3,100 4,000 2,300 2,645 2,469 2,873 1,274 1,692 456 625 578 760 2,000 330 350 - * 7 8 9 1 2 3 4 5 6 7 00 8 -9 -9 -9 -0 -0 -0 -0 -0 -0 -0 -0 0 96 97 98 00 01 02 03 04 05 06 -2 07 19 19 19 20 20 20 20 20 20 20 99 20 19 Production Exports Investment Exhibit 22: Market size and growth trends – Indian auto component market Source: ACMA (Automotive Component Manufacturers Association) * Estimated figures The Indian auto industry and auto component industry in 2006 – 07 was US$ 34 billion and US$ 15 billion. As per Government of India’s automotive mission plan 2016, the Indian auto industry and auto component industry in 2015-16 is estimated to be US$ 105 billion and US$ 40 billion respectively. It signifies that auto component industry would MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 9
  • 10. grow more than two times in the next seven years. This high growth augurs the business potential in the Indian automotive component industry in the long term. The auto component industry is facing transient challenges due to the changing global situation where 2 out of the top-3 U.S. are on the verge of filing bankruptcy. Since Indian automotive component industry is exporting to these auto majors, the reduction in the pace of growth is expected this year. This reduction is coupled with reduced growth rate of domestic vehicles sales in 2008-09. These rough times, however, are short timed in the light of Government’s automotive mission plan 2016 whereby it aims to achieve the turn over of US$ 145 billion by 2016. The growth factors i.e. lesser penetration of vehicles, growing income levels portends health growth for Indian auto and auto component industry in the long term. 1.1 Automotive Component OEM and Replacement Markets The OEM (Original Equipment Manufacturer) market is also known as the organized market segment in the Indian auto component industry. All the Tier-1 suppliers/ vendor to OEMs have their respective distribution channels in the aftermarket (or replacement market) segment. The inventory in the value chain of Indian automotive industry varies according to the size of auto component suppliers. The large strategic Tier-1 suppliers who are better connected with OEMs through ERP (Enterprise Resource Planning) system are able to manage inventories better. On the other size, the small and medium sized Indian auto component players not leveraging technology end up piling inventories due to “bull whip effect”. The Indian automotive component replacement market have various channels selling genuine and spurious parts that makes it one of the most dynamic market segment (out of the three market segments i.e. replacement demand, OEM demand and export market). According to the study conducted by IMRB International for SIAM in 2006-07, the counterfeit components constitute about 35% - 51% of private vehicle components replacement market. Lately, OEMs have started showing increasing interest in the replacement auto component. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 10
  • 11. 1.2 Foreign Direct Investment and Government Policy The automatic approval for foreign equity investment upto 100 per cent of manufacture of automobiles and component is permitted for the auto and auto component industry. The import of technology /technological up gradation on the royalty payment of 5% without any duration limit and lump sum payment of USD 2 million is also allowed under automatic route in this sector. The norms for Foreign Investment and import of technology have also been progressively liberalized over the years for manufacture of vehicles including passenger cars in order to make this sector globally competitive. With the gradual liberalization of the automobile sector since 1991, the number of manufacturing facilities in India has grown progressively. 1.3 Attractiveness of Auto Component Sub-segments and Entry Strategy The exhibit below shows that the domestic market for high grade plastic, electronics / Integrated Circuit auto parts would be best suited for the auto component imports from Thailand. The other attractive sub-segments would be rubber based intensive parts and skill intensive parts. Attractiveness Matrix for Thai Investors Low High Relative Degree of Technical Expertise Ability in cost effective supply High - Rubber Intensive parts High grade plastic, IC e.g. tyres, Accessories based electronic parts / - Skill intensive parts assemblies Low High grade plastic, IC Parts for evolving based electronic parts / technology aggregates assemblies Exhibit 40: Attractiveness matrix for Thai investors MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 11
  • 12. For business collaboration, we suggest that Thai investors should initially export these products for OEMs and aftermarket in India. Later on, when the product volumes would increase, we suggest that it should set up the assembly base in one of the auto clusters, to be selected based on initial experience. The exhibit below pictorially represents the attractive areas and the timeframe for entering across various auto component market sub-segments in India. Entry strategy for Thai Investors Degree of Attractiveness Low Medium High Plastic, silicon intensive Auto Component Sub-segments electronic parts Rubber intensive parts and accessories Parts for evolving technology aggregates Skill intensive parts covering engine parts Labour intensive parts – casting, forging etc Legend Immediate entry as OEM & aftermarket supplier Enter in these sub-segments after 1 – 2 years of immediate entry Do not enter Exhibit 42: Entry strategy for Thai investors MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 12
  • 13. 2 GLOBAL AUTO COMPONENT INDUSTRY 2.1 Global Trends in the Automotive Industry The world’s automotive manufacturing sector consists primarily of about 20 very large multinational corporations. The automotive supply sector, however, comprises of thousands of firms ranging in size from a few employees to more than 100,000. According to industry estimates, the size of the global auto component industry in the year 2008 was approximately US$1.4 trillion and is likely to grow to about US$1.9 trillion by 2015. Out of this total auto component demand by 2015, about 40% (i.e. US$ 750 billion) is likely to be sourced from low cost countries (LCCs) such as China, ASEAN countries and India. The trends that are shaping the global automotive industry are shown in the exhibit below:- Global Trends in the Automotive Industry Strategic “Tier-1" acting closely with OEMs for designs Pressure to lower Level of profitability prices continues too low Global Trends – Automotive Industry Continued Emerging markets are consolidation fastest growing markets Shared platforms & modules increasingly important Exhibit 1: Global trends in the automotive industry MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 13
  • 14. 2.2 Major Auto and Auto Component Markets The United States is far ahead of other countries when it comes to vehicle population per 1,000 vehicle driving age. It is home to the largest passenger vehicle market of any country In 2007, there were about 250 million vehicles in the United States. The exhibit below shows the penetration of LCVs across the major countries and the emerging economies like Brazil, China and India. Cars for 1,000 inhabitants in different countries Exhibit 2: Penetration of LCVs in different countries Source: Secondary Search MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 14
  • 15. The exhibit below maps vehicle penetration and nominal GDP per capita. In the long run, the emerging economies like India hold immense potential as far as global automobile industry future is concerned. GDP / Capita vs. Vehicle Density: India vis-à-vis Major Markets Exhibit 3: GDP / Capita vs. Vehicle Density: India vis-à-vis major markets The exhibit below shows per capita income and the number of inhabitants per vehicle in the year 2002 and expected ratio and per capita income in the year 2014. After comparing the potential for future auto and auto component markets, it can be deduced that the emerging economies like China and India would be at growth stage whereas the developed economies like US and Japan are the saturated stage, expected to remain stagnant or grow at less rate in the medium to long term. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 15
  • 16. Vehicle Density vs GDP/per capita Exhibit 4: Vehicle density vs GDP / per capita – Current and Estimated in 2014 Source: EIU, Goldman Sachs and A.T. Kearney analysis The above analysis clearly indicates the importance of U.S. automotive market for the global auto component industries, especially from the emerging economies and ASEAN countries. The exhibit below shows US Auto Component imports from the leading exporters:- Year Mexico Brazil China Thailand India 2001 18,469 820 1,470 380 141 2002 20,433 1,137 1,885 516 177 2003 21,477 1,319 2,363 498 191 2004 23,672 1,550 3,246 540 296 2005 25,445 1,847 4,328 535 426 Exhibit 5: Major US Auto Component Imports (In US$m): 2001-05 Source: US Census Bureau’s Foreign Trade Statistics 2001-2005 MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 16
  • 17. 2.3 Major Auto Component Companies The exhibit below shows top automotive component players and their sales figures globally in 2004 and 2005. Robert Bosch Corporation (entered in India in collaboration with MICO as MICO Bosch but now has standalone existence) and Delphi Automotive Systems are the globally ranked number one and two respectively according to their sales figures. Company Sales in 2004 Sales in 2005 Change% (USD Bn) (USD Bn) Robert Bosch Corporation 35.4 30.7 -13.28 Delphi Automotive Systems 28.6 26.9 -5.94 Denso Corporation 23.2 25 7.76 Magna International 20.6 22.8 10.68 Johnson Controls Inc. 17.7 19.2 8.47 Lear Corporation 16.9 17.1 1.18 Visteon Automotive Systems 18.7 16.9 -9.63 TRW International 12 12.6 5.00 Eaton Corporation 9.8 11.1 13.27 Exhibit 6: Top Ten Auto Component Manufacturers-2004 & 2005 Source: Various Auto reports, Database search MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 17
  • 18. 3 INDIAN AUTO COMPONENT INDUSTRY The Indian automobile ancillary sector is transforming itself from a low-volume, highly fragmented one into a competitive industry, and backed by competitive strengths, technology and transition up the value chain. Broadly the Indian automotive component industry can be divided into the organized and the unorganized segments. While the forte of the organized sector is the high valued added precision engineering products, the presence of a large unorganized sector is characteristic especially of the lower value- added segments of the industry. The ACMA-McKinsey Vision 2015 document forecasts the potential for the Indian auto component industry to be US$ 40-45 billion by 2015. Investments and exports in this segment are witnessing continuous growth. Global automobile manufactures see India as a manufacturing hub for auto components and are rapidly ramping up the value of components they source from India due to: • The cost competitiveness in terms of labor and raw material • Its established manufacturing base • Fine quality of components manufactured in India (used as original components for vehicles made by General Motors, Mercedes, IVECO and Daewoo among others). MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 18
  • 19. 3.1 Major Auto Component hubs in India In India, there are four major clusters as far as auto and auto components are concerned. The Chennai cluster has around 25 – 30% organized auto component manufacturers. The exhibit below maps major auto and auto component clusters in India:- Major Auto and Auto Component Cluster Delhi NCR and Pantnagar cluster text text Pune cluster Chennai cluster text Bengaluru cluster Exhibit 7: Major auto and auto component clusters in India Source: Secondary search MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 19
  • 20. 3.2 Transition of Indian Auto Component Industry The Indian Auto component industry has transitioned from a supplier for the global aftermarket to becoming a full-scale global Tier 1 supplier. The transition has been brought upon by increased competition from foreign players that have helped Indian auto component industry becoming auto component manufacturer and export of complex auto spare parts. The exports from Indian auto components manufacturers to U.S. top 3 automotive majors have been in excess of US $ 900 Million last year. The exhibit below shows the transition of Indian auto component industry. Transition of Indian Auto Component Industry Rotating Auto Heavy Forgings Electricals Wheel Rims Tyres & Tubes High Product Complexity Small Castings & Plastic Components Forgings Medium th Pa iti on ns Tra Hand Tools Metal bonded & Low Moulded Rubber Parts Aftermarket Tier 2-n supplier Tier 1 supplier Customer complexity Exhibit 8: Transition of Indian auto component industry MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 20
  • 21. 3.3 Auto Component Industry Cost Buildup Across the auto component industry, material cost is almost the half of the total cost build up of the total expenditure. The exhibit below shows the percentage break up of total cost in the auto component industry. Auto component industry cost item % Material Costs 50.9% Power & Fuel 4.4% Employee Costs 5.9% Other Mfg Expenses 4.1% Selling expenses 2.1% Interest & Finance Costs 1.5% Depreciation 3.3% Tax 2.3% OPBDIT Margins 16.9% NPM Margins 8.6% TOTAL 100% Exhibit 9: Auto component industry Cost Structure FY06 Source: Primary interviews and database search Out of the 5 sub-segments i.e. equipment parts, braking parts, steering parts, electrical parts and engine parts, the percentage contribution of raw material out of the total cost at 75% is highest in the braking parts sub-segment. The exhibit below provides the cost break up for the auto component by segments in the Indian auto component market:- Equipment Braking Steering Electrical Engine Parts-% Parts-% Parts-% Parts-% Parts-% Raw Material Cost 60% 74% 71% 68% 51% Power and Fuel Cost 5% 5% 6% 4% 4% Employee Cost 15% 7% 10% 10% 21% Consumable Stores 1% 3% 4% 2% 6% Selling Cost 5% 3% 3% 1% 5% Others 14% 8% 6% 15% 13% Exhibit 10: Segment-wise cost structure in the auto-component Sector FY06 Source: Primary interviews and database search MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 21
  • 22. 3.4 Classification of Auto Component Market The auto component industry can be classified into the 3 channels; as far as auto component market is concerned. The classification of auto component market, as per the market spread, is shown in the exhibit below: Classification of Auto Component Market Auto Component Market OEM demand After market demand Exports demand Auto Components Auto Accessories Exhibit 11: Classification of auto component market The OEM (Domestic and Export demand) contributes to 70% of the turnover, rest 30% of the auto component demand is generated through aftermarket or replacement demand. Break up of OEM and Replacement Demand 30% 70% OEM Demand (Including Domestic & Exports) Replacement Demand Exhibit 12: Break up of OEM and replacement demand Source: ACMA MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 22
  • 23. 3.5 Tier Structure of Auto Component Market The auto industry globally is structured based on vendor-supplier relationship with 3 to 5 nodes in the value chain ending at OEM (Original Equipment Manufacturer), that are also the automotive major. In general, the OEMs in India typically have 100 to 500 Tier-1 equipment suppliers. These vendors are further classified as per the auto component sub- segments that has been explained in the next section of this report. The tier structure in the automotive industry is shown in the exhibit below:- Tier Structure in the Auto Component Industry 2nd Tier 2nd 2nd Tier 2nd Tier 2nd Tier Tier 1st 1st Tier Tier Tier 0.5 2nd OEM Tier 2nd 2nd Tier Tier 2nd Tier 3rd 3rd 2nd Tier Tier Tier 2nd 3rd 3rd Tier Tier Tier 1st 2nd Tier Tier Tier-3 supplier to Tier-2 as well as 2nd Tier-1 supplier to OEM Tier 2nd Tier Exhibit 13: Tier structure in the auto component industry MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 23
  • 24. 3.6 Classification of Auto Components The components in the Indian automotive component market are classified in the following sub-segments:- Segments within Auto Component Industry Engine parts - Requires high precision and high quality adherence - These fall into three broad categories: Core engine parts, fuel delivery system and others. - Major parts include Pistons, piston rings, engine valves, fuel pumps etc Drive transmission & steering parts - Major sub-segments in this category include gears (tones), wheels/wheel rims, steering gears and systems - Major parts include starter motors, generators and spark plugs, gears, steering gears and systems, wheel, clutch etc - Technology intensive, top ten players account for about 80% of the total segment size - Size of replacement market for this segment is likely to increase esp. for wheels Body and chassis - The chassis is the skeleton upon which all other components are positioned Auto Component - The parts under this segment include underbody, closure, body side, doors, Industry plastic-molded parts and exhaust systems etc Suspension & braking parts - Major sub-segments in this category are shock absorbers, leaf springs and brake shoe assembly segments - Gabriel India Ltd and Munjal Showa Ltd are the majors in the shock absorber segment Electrical parts - New technology in cars and electric start two-wheelers are leading to the growth of this segment - Major parts include carburettors, starter motors, generators, bimetal bearings, distributors, air conditioning unit etc Equipment & Others - Major equipment parts include headlights, dashboard instruments, wiper motors and electric horns etc. Other components include sheet metal components and plastic moulded parts Exhibit 14: Segments within auto component industry MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 24
  • 25. 3.7 Major Automobile Players The significant growth in the Indian automobile market as a result of growing income and purchase power has provided opportunities to all the global automobile players to set up their base in India in the last one decade. The setting up of new plants has provided cluster development of automobile and automotive component market in India. The exhibit below shows the major players in the Indian market who have manufacturing units in India:- Passenger Cars Commercial Vehicles Two-Wheelers Three-Wheelers Maruti Suzuki Ashok Leyland Hero Honda Bajaj Auto Hyundai Tata Motors Bajaj Auto Piaggio Tata Motors Eicher Motors TVS Motors Mahindra & Mahindra Honda Swaraj Mazda Royal Enfield Motors TVS Motors Mahindra & Mahindra Volvo Kinetic Motors Tata Motors Toyota MAN-Force Suzuki Motors Force Motors Fiat Yamaha Motors Hindustan Motors Honda General Motors LML India Ford Volkswagen Renault Mercedes Benz Skoda BMW Volvo Exhibit 15: Auto Component Sub Segments and Major Players in Indian Markets MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 25
  • 26. 3.8 Major Automobile Component Players (Two, Three and Four Wheeler players) There is not any distinction between the two wheeler and four wheeler automobile component players in the Indian automobile component industry. The major organized players who are catering to two wheeler OEMs are also catering to four wheeler OEMs. However, for some niche commercial vehicle components, due to specialized load bearing and design requirements, some automobile component players are the vendors only to commercial vehicles. The exhibit below shows the major players operating in the key sub-segments in the product segments of the auto components:- Product Segment Key Sub-Segments Major Players Gears & Drive 1. Rico Auto Inds Clutches 2. Automotive Axles Transmission and Steering Axles 3. Wheels India Ltd. Others Sona Koyo Steer. GKN Driveline (India) Starter Motors, Generator, Denso Distributor, Spark Plugs, Motherson Sumi Ignition Coil, Flywheel MICO Electrical Parts Magnet, Voltage Regulator, Minda Industries Electrical Ignition India Nippon Lucas TVS Escorts India Pistons Goetze (India) Pistons India Pistons Piston Rings Rane Engine Valves Engine Parts Engine Valves Shriram Pistons & Rings Carburettors Spaco Carburettors Fuel Delivery System Ucal Fuel Lucas TVS MICO Germany Lumax, Autolite, Phoenix Headlight Lamps Premiere Instruments & Equipment Dashboard Controls Jay Bharat Maruti, Omax Sheet Metal Auto, JBM tools Brake System Automotive Axles Suspension and Braking Brake Linings Brakes India MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 26
  • 27. Shock Absorbers Kalyani Brakes Allied Nippon Rane Brake Lining Sundaram Brake Gabriel India Munjal Showa Fan Belts Rico Auto Others Sheet Metal Rico Auto Exhibit 16: Auto Component Sub Segments and Major Players in Indian Markets Source: Database search “Top 50 auto component companies in India would have around 1000 auto component units across clusters. The vendors supplying to OEMs can be considered as organized segment players. These (organized players) would be around 5,000 – 6,000. The total players including unorganized segment would be around 15,000.” - Sr. Vice President, One of the leading Tier-1 component suppliers Since components used in Commercial Vehicles and Tractors call for the properties of high strength and load requirement, it was, therefore, observed that the operation of these parts manufacturers are following in nature: a) The manufacturer is a niche player exclusively catering to the need of Commercial Vehicle or Tractor replacement market segment OR b) A large organized player supplying to the traditional 2& 3 wheeler and passenger vehicles component markets has established a separate SBU (Strategic Business Unit) for servicing the need of Commercial Vehicles and Tractors segment 3.9 Foreign Collaboration in the Auto Component Industry The Indian automotive industry is characterized by a strong competition between increasingly quality conscious manufacturers. The large, highly skilled but low cost manufacturing base makes partnering linkages with overseas players attractive. These strengths coupled with India’s well established strengths in IT/software combined together to make India an emerging player in this sector. However, the industry needs to continue to increase its quality standards and develop new products to compete globally. Many domestic manufacturers have successfully entered into strategic alliances/ MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 27
  • 28. collaborations while others are actively chalking out their plans. Many of the world’s leading Tier-1 suppliers have set up manufacturing facilities in India including Bosch, Delphi, Visteon and Denso etc. Additionally, there is a well-developed domestic component and ancillary industry with some suppliers already meeting global technical and quality standards at the Tier-1 level. Some of India’s leading OES (Original Equipment Suppliers) include TACO, Bharat Forge, Sundaram Clayton, and Sundaram Brake Linings that have proven quality track record. However, many other suppliers lack such competence and are looking to upgrade their process/technologies to remain competitive. The exhibit below shows a part of Indian auto companies that have collaborated with the foreign partners in the Indian market:- Name of Foreign Name of Indian Company Item of Manufacture Collaborators Amtek Auto Ltd., Gurgaon Bendo Kogyo, Japan Fly wheel ring gears Jay Bharat Maruti Ltd., Gurgaon Allied Signal, USA Seat belts and Air bags Subros Ltd., New Delhi Allied Signal, USA Catalytic converters Exhaust Systems, Mark Exhaust Systems Ltd., Gurgaon Sankei Giken, In.Co., Japan Catalytic Converters Saint Gobain Vitgrage, Laminated Safety Glass Atul Glass Industries Ltd., New Delhi France Alcan Deutschland GmbH, Pistons & Piston Rings Menon Pistons Ltd., Kholapur Germany Rockwell International Corp., Axle systems Automotive Axles Ltd., Mysore USA Blue Chip Products Inc., Water pumps Autolec Industries, Madras USA Spicer India Ltd., New Delhi Dana Corp., USA Engine bearings Ball joints & Suspension Sona Steering Systems Ltd., New Delhi Somic Ishikawa, Japan joints Asbestos free brake Sona Steering Systems Ltd., New Delhi Fedoro, UK linings Sona Steering Systems Ltd., New Delhi Matsuda Industries, Japan Cold forging Haryana Sheet Glass Ltd., Haryana Pilkington Plc., UK Laminated sheet glass Johnson Controls Inc., USA Seating systems Sommer Allibert, France Interiors and Plastics Yazaki, Japan Wiring harness Transmission of steering Tata Industries Ltd., Bombay ZF, Germany systems NIFCO, Japan Plastic Fasteners Brake systems, Electrical ITT, USA & wiper systems Exhibit 17: Indian Auto Component-Foreign Collaborations (2006) Source: Database search MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 28
  • 29. 4 INDUSTRY AND MARKET ANALYSIS The macro environment of the Indian auto component industry can be assessed by understanding the social / consumer shifts, understanding its political and legal environment, technological environment and economic shifts. The micro environment of the industry can be assessed under the Porter’s 5 forces framework by understanding the entry barriers, threats and supplier / buyer power. Merging the two assessment frameworks provides an indication of macros (at a broader level) and micro (at an industry level) factors influencing the entry of new players in the market. This 9-forces analysis on a framework (comprising macro and micro factors) for Indian auto component industry is done in the exhibit below:- MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 29
  • 30. 4.1 Macro and Micro Environment Analysis: Indian Auto Component Market Market Analysis – Indian Auto Component Market Technological shifts Political / Legal Environment - Fast becoming global hub for R&D: GM, Daimler - FDI growing due to competitive advantage; witnessed Entry Barriers Chrysler, Bosch, Suzuki, Johnson Controls etc. have set CAGR of 21.7% during 2002 – 07. The FDI was USD 7.2 - OEMs’ “inclusive growth” ensuring long term up development centres in India. Billion in 2007 – 08 relationship especially for high value-adding items - Casting and forging processes in India 25 to 30 % lower - Investment Commission of India facilitating FDI in all - Foreign suppliers supplying to global auto majors with than western counterparts. forms local knowledge and expertise may have easy access - 5 Indian auto component companies received coveted - No repatriation issues after paying taxes Deming Prize, largest number outside Japan. Supplier Power Industry Competitors Consumer Power - 450 – 500 mid to large players with - Tier structure supporting vendor - Auto OEMs have average 2 suppliers around 6000 – 7000 units in addition to relationship to ensure competitiveness around 10,000 units in unorganized - Most Tier – 3 suppliers are small units - New auto clusters being developed segment. largely from unorganized segment with OEMs and major ancillaries - Technical tie ups and R&D ensuring at - least 2 major players across segments Economic shifts Social / Consumer shifts Threat of Substitutes - Concentration of disposable income in top 6 – 8 cities - Auto component industry – incubator to entrepreneurship - Less threat to substitute for organized players - Rising spending patterns on “pampering” therapies initiatives especially for less value adding components working with OEMs and emphasizing on R&D - International economic environment augurs cautious - OEMs developing and launching “India centric” vehicles for future needs approach after understanding Indian consumers’ demands - Unorganized units stand chances for greater threat Exhibit 18: 9-Force Market Analysis of Indian auto component market MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 30
  • 31. The macro and micro environment can be analyzed by looking at Porter’s five forces for micro environment analysis and PEST analysis for analyzing macro environment of the auto component industry. In the exhibit above, while looking at competitors, there are 450 – 500 medium to large players with around 6000 – 7000 units in addition to around 10,000 units in the unorganized segment. This distribution highlight that auto component industry is dominated by unorganized players. It provides opportunity for organized Thai investors to provide the products identified as their core competence in the later part of the report. Analyzing other aspects like entry barriers, threat of substitute and supplier and consumer power also helps in understanding the Indian auto component market and devising the entry strategy and positioning plank for the products supplied by the entrepreneurs from Thailand to Indian auto component market. 4.2 SWOT Analysis: Indian Auto Component Market The classical tool to assess the industry environment is through SWOT analysis. The exhibit below identifies Strengths, Weaknesses, Opportunities and Threats (SWOT analysis) in the Indian Auto Component Industry:- MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 31
  • 32. SWOT Analysis – Auto Component Industry Strength KEY FEATURES Weakness ▪ Is globally cost competitive ▪ Annual production turnover of ▪ Industry has low level of research ▪ Adheres to strict quality Rs. 210 billion (US $4.5 billion): and development capability small by global standards controls ▪ Around 5,000 players in the ▪ Industry is exposed to cyclical ▪ Has access to latest unorganised sector and 400 in the downturns in the automotive technology organised sector. industry ▪ Provides support to critical ▪ Share of unorganised sector at ▪ Most component companies are infrastructure and metal 23%: caters primarily to dependent on global majors for replacement market industries technology ▪ Share of organised sector at 77%: caters primarily to Original Equipment Manufacturers, exports and replacement market ▪ All prominent companies have technological tie-ups with global majors ▪ Manufactures products that may be classified into six categories: Engine Parts; Electrical Parts; Opportunities Drive, Transmission & Steering Threats ▪ May serve as sourcing hub for Parts; Suspension & Braking Parts; ▪ The presence of a large Equipment; and Others global automobile majors counterfeit components market ▪ The fortunes of the industry are ▪ Significant export largely driven by the automotive poses a significant threat opportunities may be realised industry ▪ Pressure on prices from through diversification of ▪ Posted a decline in margins and OEMs continues export basket returns in last five years till ▪ Imports pose price based FY2002: working capital cycle ▪ Implementation of Value- competition in the replacement increased during the same period Added-Tax (VAT) in FY2004 market will negate the cascading ▪ Further marginalization of impact of prices smaller players likely Exhibit 19: SWOT Analysis – Indian auto component industry With the growing sales of automobiles, new global OEMs are entering in the Indian automotive industry which in turn provides the auto component industry the opportunity to register robust growth over next 5 – 8 years. The component industry has not more than 50 players with turnover of more than US$ 500 million per annum. Around 70 – 80% of the total numbers of players, at the bottom of the pyramid, have revenues of less than US$ 1 million per annum. The growing automobile demand and the increasing awareness to purchase genuine spare parts in the aftermarket poses attractive market opportunities for the two and four wheeler auto component manufacturers. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 32
  • 33. 5 MARKET SIZE AND GROWTH FORECASTS 5.1 Global auto component market size and growth estimates Global Automotive Component Market (US$ billions) Exhibit 20: Growth trends of global automotive component market Source: Database search As shown in the exhibit above, the global automotive components consumption is expected to grow from US$ 1.2 trillion in 2003 to US$ 1.65 trillion in 2015 (exhibit below). As per one of the reports, of this US$ 1.65 trillion, LCC (Low Cost Country) players can theoretically address roughly 42 per cent or US$ 700 billion. They cannot address US$ 425 billion or 26 per cent of the market that will primarily be manufactured by OEMs in their home countries. Another US$ 525 billion or 32 per cent of the global market will be ruled out because of practical difficulties in off-shoring or because it will yield negligible savings. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 33
  • 34. 5.2 Indian auto component market size and growth estimates According to Automotive Component Manufacturers’ Association (ACMA), the production of automotive component in India was US$ 18 billion. It is growing at CAGR of 27% since 2002-03. The investment in the Indian auto component industry is also gaining momentum with almost all major global automotive component manufacturers are setting up their plants in India. 5.2.1 Production (in Number) and Growth rates of all vehicle categories including two wheelers The exhibit below indicates that in 2006-2007, out of the total automobiles market size of around 1,10,65,000 vehicles, 94,42,000 or around 85% of the vehicles were two wheelers. On an average, the overall annual growth rate of vehicles in the last 5 years has been in excess of 15%. Category 2002-03 2003-04 2004-05 2005-06 2006-07 Passenger Car 609 843 1018 1113 1323 Utility Vehicle 114 146 192 197 222 Commercial Vehicle 204 275 354 391 520 Two-Wheeler 5076 5623 6530 7609 9442 Three-Wheeler 277 356 374 434 556 Grand Total 6280 7244 8468 9744 11065 Growth Rate 18.13% 15.34% 16.90% 15.06% 13.55% All Number in '000 units while Growth Rate is in percentage Source: Ministry of Heavy Industries, Government of India Exhibit 21: Production and growth rates of all vehicle categories Source: ACMA Above table also points out that the two-wheelers and passenger cars have been the most significant product categories (combined share -97%) and growing steadily over the past few years. The two wheeler replacement auto component market also holds significant importance due to the sheer volumes. Therefore, the 2-wheeler automotive component market cannot be ignored while gauging the attractiveness of automotive component market of India. The synergies between the two-wheeler & four wheeler component market also enable two-wheeler component manufacturers to service the four wheeler segment easily. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 34
  • 35. 5.2.2 Consolidated Production, Export and Investment in value terms As per the exhibit below, the exports in 2007 – 08 were US $ 3.6 billion, out of these close to US $ 1 billion auto components were exported to top-3 US automotive majors i.e. GM, Ford and Chrysler. Indian Automotive Component Market Auto Component Production 20,000 18,000 18,000 15,000 16,000 (In USD Million) 14,000 12,000 12,000 10,000 8,700 6,730 7,200 8,000 5,430 5,400 6,000 3,894 3,965 4,470 3,750 4,400 3,615 3,278 3,008 3,249 3,100 4,000 2,300 2,645 2,469 2,873 1,274 1,692 456 625 578 760 2,000 330 350 - * 7 8 9 1 2 3 4 5 6 7 00 8 -9 -9 -9 -0 -0 -0 -0 -0 -0 -0 -0 0 96 97 98 00 01 02 03 04 05 06 -2 07 19 19 19 20 20 20 20 20 20 20 99 20 19 Production Exports Investment Exhibit 22: Market size and growth trends – Indian auto component market Source: ACMA (Automotive Component Manufacturers’ Association) As per the exhibit above the consolidated production of the two, three and four wheeler auto component industry is growing at CAGR of 25 – 27% from the past 4 – 5 years. The production is catering to both the domestic demand, coming from OEM and replacement demand, and the growing rate of exports. The investment in the auto component industry has also been doubled to USD 7.2 Billion in the last three years. This highlights the growth momentum in the Indian auto component industry. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 35
  • 36. 5.2.3 Value wise break up of sub-segments – two and four wheelers The two wheeler automotive component market like the four wheeler automotive component market can be classified into the same sub-segments categories. Out of the consolidated automotive component market, the engine parts have the major share among the other auto components. It accounts for 31% of the total auto component market (in value terms). The equipments, electrical and other parts account for 10%, 12% and 7% respectively of the total auto component market size (in value terms). The break up of the auto component industry (in value terms including 2 and 4 wheeler components) is shown in the pie chart below: Beakup of Various Segments in Indian Auto Component Industry (In Value terms) 31% 19% 7% 12% 9% 10% 12% Engine parts Drive transmission & steering parts Body & chassis Suspension & braking parts Equipment Electrical parts Others Exhibit 23: Percentage breakup of sub-segments in the Indian auto component industry Source: ACMA (Automotive Component Manufacturers Association of India) 5.2.4 Import estimates and trends (for 2 and 4 wheelers) The imports for the auto components are ranging 2-4% for the total replacement market (which is 30% of total auto component demand in India). In the OEM demand, import of auto-components is negligible (less than 1%), as it can be identified from the comment below:- MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 36
  • 37. “All OEMs have their vendors located in India. However, some OEMs like us (Ashok Leyland) have set up their offices in China from where we are importing some components that are cost effective. These components would be less than 1% of the total auto component requirements - Strategic Sourcing Official from one of leading Vehicle manufacturer Within imports of auto components, Engine and Suspension / Braking have relatively higher proportion in imports whereas Transmission and Equipments have lesser proportion. The table below highlights the items that are either high in import proportion (in value terms) or are growing at rapid rate i.e. 50% or more. India imported US$ 20 million auto components from China in 2004 – 05 whereas the imports from ASEAN countries were close to US$ 73 million during the same time. The estimated imports (based on the growth trends) from China and ASEAN countries in 2008 – 09 would be around US$ 120 – 150 million and US$ 350 – 400 million respectively. Auto component import Total Import – 2004-05 (US $ Million) Growth Rate (2001-05) (OEM + Replacement) Imports Imports Share of Imports Imports from All All Components detail from from China & from China ASEAN Imports Imports China ASEAN ASEAN Parts and accessory of motor 543.38 3.98 61.16 12% 28% 28% 58% vehicles Engine parts 203.19 8.99 3.09 6% 15% 113% 24% Electrical parts and accessories 29.80 0.68 0.1 3% 26% 63% -50% Bumpers and parts 23.09 0.23 1.59 8% 69% 74% 288% Injection pumps, oil pumps, 22.67 0.73 0.01 3% 39% 111% -29% water pumps Drive axles with differential 18.63 0.01 0.87 5% 50% - Lighting equipment 17.46 1.8 2.01 22% 24% 14% 107% Other Brakes/Servo brakes 17.20 0.9 0.23 7% 46% 63% -17% Starter motors 11.16 0.3 1.44 16% 33% 166% 5% Clutches 9.17 0.2 0.74 10% 25% 26% 147% Wheels 7.86 0.75 0.29 13% 80% 127% 14% Steering wheels and columns 7.06 0.01 0.45 7% 45% 21% 208% Rear view mirror 4.23 0.74 0.6 32% 37% 104% 97% Laminated safety glass 1.84 0.63 0.29 50% 87% 281% 313% Total 916.7 20.0 72.9 30% 55% 49% Exhibit 24: Auto component imports (OEM + Replacement market) Source: ACMA (Automotive Component Manufacturers Association, DGFT (Directorate General of Foreign Trade) MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 37
  • 38. The highlighted components above are the promising auto component products for both two wheelers and four wheelers auto components that have are either high on value or the rate of growth of import is significantly higher. These items could be looked as the potential export items by Thai investors to export to India. The consumable items markets like injection pumps, oil pumps, bumper and parts and wheels are growing at faster rate in the replacement market due to increase vehicle population. We expect the share of imported parts (especially from China and ASEAN countries including Thailand) to grow in the future because of the two major reasons:-  FTA’s that India has sign with a number of countries including Thailand would result in increase in imported parts  Launch of similar products in India and China / ASEAN. 5.2.5 Auto Component Export Destinations The U.S. and European markets account for 28% each of the total exports from the Indian auto component companies. The exhibit below shows the break up of the total auto component export markets across the major auto importing markets. Auto Component Export Destinations (In Value terms) 28% 27% 28% 4% 2% 11% U.S. Europe Asia Africa Australia Others Exhibit 25: Indian auto component export destinations Source: ACMA MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 38
  • 39. 5.2.6 Trends in growth and margins – Two and Four wheelers As mentioned in the section 5.2.2 above, the automobile market is growing at CAGR of 25 – 27%. Notwithstanding the temporary global economic meltdown, it is expected that the domestic demand for automobiles would grow unabatedly over the next 3 – 5 years. The exhibit below shows the gross margin and net margin at the distribution and retailer level:- Gross Margins Net Margins Distribution Ranges between 12 – 15% Ranges between 4 – 6% based Margin based on type of part and on type of part and type of type of manufacturer manufacturer Retail Ranges between 14 – 18% Ranges between 6 – 8% based Margin based on type of part and on type of part and type of type of manufacturer manufacturer Exhibit 26: Distributor and Retailer Margin The average distribution margin per players (made by distributors / wholesalers) is dependent on the number of layers in the channel. The margins and incentives play a key role in pushing the product at the retail end. The margins are relatively higher for electrical parts and brake & suspension parts. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 39
  • 40. 6 AUTO COMPONENT OEM AND REPLACEMENT MARKET This section highlights OEM supply chain and inventory management aspects for small and large auto component supplier. In the replacement market segment, changes in the replacement market including the increasing focus of OEM on aftermarket in the recent years and the channel structure have been highlighted in this chapter. 6.1 OEM Market in the Indian auto component industry The OEM market is also known as the organized market segment in the Indian auto component industry. All the Tier-1 automotive component vendors have their respective distribution channels in the aftermarket segment. Typically, an OEM works with around 100 – 200 Tier-1 suppliers and around 500 Tier-3 / Tier-2 suppliers (to Tier-2 / Tier 1 suppliers), depending upon the diversity of product line offerings. 6.2 OEM Component Sourcing The automotive manufacturing industry in India is on par with the globally competitive markets. All the plants are typically connected with ERP systems with their strategic vendors and distribution channels that enable them to control raw material, WIP (Work In Process) and finished products (vehicles) inventory. The exhibit below shows typical order-to-delivery process supply chain in the automotive industry. MARKET ATTRACTIVENESS OF INDIAN AUTO COMPONENT INDUSTRY 40