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Wa l k Advanced technologies create... toget h e r A nnual R eport 2012 April 1, 2011–March 31, 2012 New materials make...
Toray Profile: Overview and Philosophy We are involved in global manufacturing, marketing and sales in three business categories covering six seg- ments: Foundation Businesses (Fibers & Textiles, Plastics & Chemicals), Strategically Expanding Businesses (IT-related Products, Carbon Fiber Composite Materials) and Intensively Developing and Expanding Busi- nesses (Environment & Engineering, Life Science). Our products are found in many everyday items, including apparel, interior products, home appliances and electronic products, as well as in materials and parts for automobiles and aircraft, IT products and water treatment facilities. Today, we are active in 23 countries and regions. To successfully conduct our day-to-day operations, we rely on the strong chemistry that we have created with our stakeholders, including Toray Group employees, our customers and business partners, the people of the countries and regions in which we are active, our stockholders and people working for financial institutions. “Contributing to society through the creation of new value with innovative ideas, technologies and products”—this is Toray Group’s corporate philosophy. We will continue to put this philosophy into practice by creating new value in the spirit of respect for all of our stakeholders. Corporate Philosophy Contributing to society through the creation of new value with innovative ideas, technologies and products Corporate Missions For our customers To provide new value to our customers through high-quality products and superior services For our employees To provide our employees with opportunities for self development in a challenging environment For our stockholders To provide our stockholders with dependable and trustworthy management For society To establish ties and develop mutual trust as a responsible corporate citizen Imagine it... CAUTIONARY STATEMENT WITH RESPECT TO FORWARD-LOOKING STATEMENTS Descriptions of predicted business results, projections and business plans contained in this annual report are based on forecasts and assumptions regarding the future business environment made at the present time. This annual report is not a guarantee of the Company’s future business performance. 02
c a n h elp to t h a t T oray e b e l ieve fo r pe ople W u a li ty of life the q in the improve re ating va lu e ere b y c everywh d m at e rials. o f a dvance form , cie ty . F o r example so r to transform ally h a v e th ep o w e r h a v e dramatic Materials fibe o f carbon a h a n d ligh t n e s s s e n g e r jets. As g t y pa s the stren n s umed b ree- t h e e n erg y c o w e e n joy the f reduced n era in w hich ized e n o w live in a ie n t m edium-s result, w effic on highly sed t r a v e l the w o r ld e t ic fi b ers are u dom to ynth c e d f u n ctional s ur advan aircraft. O r m innerwea r. easy c e li g h t ye t w a ia ls is n ever an to produ ate r r e a t io n of new m e r ia ls t h a t t h e c m a t Howeve r, ded h - v a lu e - a d t h e v a r io u s h ig u lt s o f a relent- of res t a s k . A ll o r ld are the r o u g h t to t h e w g y d e v e lopment. sb nolo Toray ha and tech m e n t to re se a rch s t a r t e d to trans- mit ve less com e d b y Toray ha evelo p e w m a terials d N ty. a s p e c t s of socie ny form ma 03
Wa l k ANNUAL REPORT 2012 toget h e r Contents Advanced technologies create... 05 05 New materials make... 05 Message 1.........Reducing weight 07 Message 2.........Functional apparel 09 Message 3.........Expanding “New energy” 11 Message 4.........New advances in medical care 13 Message 5.........Securing water resources To Toray Stockholders and 16 Investors 23 Toray’s Global Operations 28 Toray Group Segments 30 31 32 33 Fibers & Textiles Plastics & Chemicals IT-related Products Carbon Fiber Composite Materials 16 34 Environment & Engineering 35 Life Science 36 R&D and Intellectual Property 42 Sustainable Management 52 Corporate Information 42 55 Financial Section 91 Investor Information and Corporate Data 28
Message 1 Reducing weight Weight reduction has always been a priority for design- ers of all kinds of vehicles. Whether in automobiles, aircraft or space rockets, less weight means lower fuel consumption and greater range. Our continual quest for lighter materials has led from iron to alloys of alu- minum, titanium and other metals, and to plastics and other substances. The most promising solution to our need for lighter materials is carbon fiber. With only one-quarter the weight of steel, carbon fiber is 10 times stronger. This combination of strength and lightness has resulted in the use of carbon fiber in a growing range of aircraft parts. Carbon fiber composite materials make up 50% by weight of the fuselage of the Boeing 787 passenger jet, which went into service in 2011 and has started to cross the world’s skies. 05
Carbon fiber—a light, strong body material Although carbon fiber is attracting renewed interest today, its industrial development be- gan around 50 years ago. Since then, many companies have started to develop commer- cial applications to capture the many advantages of carbon fiber, including its lightness and strength and the fact it never rusts. However, most of these companies have since abandoned carbon fiber because of the many years required to recover investments, and because of the difficulty of producing high-quality fibers reliably. Toray believes in the future potential of carbon fiber and has worked relentlessly to cre- ate markets and develop technology. We anticipated the emergence of major new markets n based on carbon fiber applications in such fields as aerospace, sports and general industry. We have since worked to harness the growth of these markets by building global opera- io tions based on production facilities in Japan, North America and France. With a market t share in excess of 30%, Toray is today the world’s top* manufacturer of carbon fiber. c *By sales volume, based on Toray estimates TEEWAVE ® AR1—Concept Electric Vehicle Can carbon fiber composite materials revo- lutionize the automobile? Toray responded to this question by unveiling the electric TEEWAVE® AR1 concept vehicle at the 2011 .. .in A Tokyo Motor Show. The TEEWAVE ® AR1 was designed by Gordon Murray, former chief designer for the McLaren Formula 1 team. By using carbon fiber composite ma- terials, the body weight was reduced to just 846 kg. Toray materials were also used in the battery, motor and other parts to cre- ate a concept vehicle that would embody Toray’s total capabilities. y of ke e ight by w e re- p 50% l ag e. Th ake u fus e car- r ia ls m n g s and c tio ns in mat e its w i redu only 8 7 p osite u ding s and n o t the . ing 7 co m in c l avin g are craft Boe n fiber in g 787, . Fuel s w e ight th is air o e t d n ae s y car b Bo eigh redu ce er i incre Tora ts of the io n in w o m r bo n fib e to r n t gf r f ca ssib l neve pone duc com m a tic re s re sultin ive use o b e e n po n fi ber a is dr a ion tens lso rbo d at sult e e miss th e ex it has a t t h at ca a in taine o diox id from ger, fac em ble t bon r e sult is s tron tio n , the in c an b s be en a o di ab fits t usela ge In ad the c eing ha bene the f ws. el in r, Bo ced. c au se e w in d o id ity le v o n fib e er p rodu e arb t ev B of th the h um ng c rcraf size that y usi er ai the ns e l. B e n g mea lev ass rusts table ble p co mfor o m forta mor e ost c 06 ate the m cr e
Message 2 Functional apparel Natural fibers such as cotton, wool, silk and flax have been used in apparel since ancient times. Each of these materials has been used for different purposes, based not only on fashion perspectives but also on specific advantages, such as warmth, moisture resistance, the capacity to absorb perspiration and ease of drying. With the emergence of synthetic fibers, it became possible to use chemistry to create fibers with the same functions as these natural materials. The abil- ity to supply synthetic fibers cheaply and reliably has made a major contribution to the world of apparel. Synthetic fibers have continued to evolve, and today they offer increasingly diverse and sophisticated func- tions to enhance wearer comfort. There are thin, light synthetic textiles that not only conserve heat produced by the wearer’s body, but also generate heat when worn and have excellent perspira- tion absorption characteristics. Products such as these are changing our perceptions of apparel and transform- ing our lifestyles. 07
HEATTECH—amazing apparel that creates its own warmth Many people became aware of the potential of functional apparel when they first encoun- tered HEATTECH. Developed jointly by Toray and UNIQLO, it offers a range of functions that include not only heat retention, perspiration absorption and rapid drying, but also the ability to create heat from the wearer’s perspiration. HEATTECH first appeared in 2003. Initially, it was made by combining acrylic fibers, which have excellent heat retention properties, with rayon, which can generate warmth from water vapor. In the following year, polyester fiber was added to provide perspiration absorption and rapid drying characteristics. In 2007, poly- urethane fiber was added to give the material stretchability. In that year, consumers bought 20 million items made from HEATTECH, a combination of four different fibers. The product has continued to evolve, and sales volumes have risen to 50 million in 2009 and 100 million in 2011. In 2006, Toray and UNIQLO formed a stra- tegic partnership, under which they have since created a total industry, including planning, development, production and distribution at all stages from raw materials to finished prod- ucts. Under a subsequent strategic partnership agreement, signed in 2011, the two compa- nies aim to achieve cumulative transactions amounting to ¥400 billion by 2015. Under this strategic partnership, Toray and UNIQLO have created many hit products, in- cluding not only HEATTECH, but also Silky Dry and Ultra Light Down. 08 ...in Betterment
Message 3 Expanding “New energy” Electric power is an essential source of energy for soci- ety, industry and individuals. To ensure the reliable and sustainable supply of electric power in the future, we will need to make increased use of renewable energy, including solar power, wind power and fuel cells, which have high energy efficiency and qualify as low-emission devices. This will require the development of revolution- ary devices and materials that can be used to create a new generation of practical and efficient power genera- tion systems under the heading of “New energy.” There is also renewed awareness of the importance of storage batteries in ensuring the efficient use of valuable electric power. Traditionally batteries were used mainly to power electronic devices and other small items, or in auxiliary roles, such as power for mo- tor vehicle starter motors. In the future they will be the prime sources of power for electric vehicles. Storage batteries are also expected to be used increasingly to stabilize the supply of electric power from sources that are affected by weather conditions by storing power when demand is low and supplying it at peak times. 09
...in Progress Advanced materials the key to a new future for batteries The core technologies for Toray’s research and development efforts in the field of advanced materials are organic synthetic chemistry, polymer chemistry, biotechnology and nanotechnol- ogy. Toray has identified a number of product categories as offering opportunities for the appli- cation of its technology development capabilities in the next-generation energy technology. We are focusing in particular on battery materials, solar cells, lithium-ion batteries and fuel cells. By 2020, the solar cell market is expected to reach ¥12 trillion. Toray supplies a range of advanced functional materials, including polyester film for use as back sheets. The grow- ing popularity of hybrid and electric vehicles is expected to boost the market for lithium-ion batteries to over ¥5 trillion by 2020. Toray Tonen Specialty Separator Godo Kaisha, which manufactures and sells battery separator film, was made a wholly owned subsidiary, and Toray Battery Separator Film Co., Ltd. was established. Toray is also developing fuel cell ma- terials. By offering a wide range of materials, Toray aims to become the world’s leading integrated manufacturer of battery materials. 10
Message 4 New advances in medical care New advances in medical technology not only help to open up new fields and provide cures for previously in- curable diseases, but also contribute to improvements in the safety and quality of medicine, including the re- duction of the burden on patients. For example, the evo- lution of dialyzers for use in hemodialysis is providing improvements in the effectiveness of this treatment. One of the new surgical techniques that have helped to reduce the impact on patients in recent years is catheter surgery. New treatment methods result both from advances in medical technology and also from the development and improvement of new products. Medical science will continue to move forward in directions that help to reduce the burden on patients. 11
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Message 5 Securing water resources The Earth is sometimes described as a “water planet.” However, 97.5% of the Earth’s water is seawater, and freshwater resources make up only 2.5% of the total. The amount of freshwater available for use by human beings for daily life and industrial activities is even smaller, at just 0.01% of the total. Freshwater is a pre- cious resource, and yet the amount available continues to shrink due to climate change and environmental damage. At the same time, demand for water contin- ues to expand because of world population growth and economic development in emerging countries. Water shortages have become a serious social problem in many parts of the world. Efforts are now being made to mitigate water shortages through water conserva- tion, environmental preservation and other measures. However, seawater desalination is increasingly seen as a more effective solution in the many regions that are naturally short of water resources. The key product in a desalination plant is the reverse osmosis membrane. 13
...in Conception Reverse osmosis membranes—turning seawater into drinking water Desalination plants traditionally used evaporation to turn seawater into drinking water. Today, however, sys- tems based on water treatment membranes are being used increasingly because of advantages that include lower energy consumption and costs. Toray developed reverse osmosis (RO) membranes that are ideal for de- salination by improving related technologies, including nanotechnology-based polymer separation membrane technology. As a result, Toray has gained a 30%*1 share of the world market. In addition to RO membranes, there are three other types of membranes that differ according to their wa- ter permeability and the substances that they can remove. Toray enjoys an important advantage because it de- velops and manufactures all types of these membranes. Because it can offer the most suitable membranes for any application, Toray has established a substantial track record, not only in the area of seawater desalination, but also in other fields, such as wastewater reuse. Toray has gained an excellent reputation for water treatment membrane technology. In recent years we have achieved considerable success in the control of microscopic structures, as evidenced by our ability to create holes with sub-nanometer precision. We have used this technology to produce RO membranes with the world best boron-removal performance*2 and the capability to produce large amounts of drinking water. Toray membranes have been used in major projects, including the largest desalination plants in Africa (Algeria) and Asia (Singapore). They are also being used increasingly in the rapidly expanding Chinese market. RO mem- branes already shipped by Toray produce sufficient drinking water for 98 million people around the world. *1 Estimated by Toray on the basis of shipment volumes *2 Boron levels in drinking water are regulated because of its harmful effects when ingested, including toxic effects on the repro- ductive system. 14
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Design it... 16
To Toray Stockholders and Investors Akihiro Nikkaku President 17
To Toray Stockholders and Investors I would like to begin this report by expressing our sincere appre- Project AP-G 2013 not only pursues an energetic growth ciation for the ongoing support and understanding of our stock- strategy based on expansion in growing business fields and re- holders and investors. We are committed to grow sustainably gions, but also strengthens our overall cost competitiveness. based on the realization of our corporate philosophy of contrib- The goal is a business structure capable of supporting sus- uting to society through the creation of new value with innova- tainable growth. Within that structure, the Fibers & Textiles and tive ideas, technologies and products. This report contains our Plastics & Chemicals segments are positioned as “Foundation consolidated financial results for fiscal 2011 (ended March 31, Businesses,” driving steady business expansion with increases in 2012), together with strategies outlining Toray Group’s priorities revenues and profits. The IT-related Products and Carbon Fiber and future direction. Composite Materials segments are positioned as “Strategically Expanding Businesses,” to drive revenues and profit growth over the medium and long term. And, the Environment & Engineering Launch of the medium-term management and Life Science segments are positioned as “Intensively Devel- program—Project AP-G 2013 oping and Expanding Businesses,” the next drivers of revenue Fiscal 2011 was affected by negative events, not least of which and profit growth. was the Great East Japan Earthquake, but also including mas- In fiscal 2011, trends in the IT-related Products segment sive floods in Thailand, the historically high yen appreciation were affected by production cutbacks in the flat-panel display and credit uncertainty in Europe. Toray Group was successful in industry resulting from a downturn in the flat-panel television minimizing the impact of these situations with the cooperation market. However, our financial performance was steady, thanks of our business partners and the hard work of our employees. In to generally strong sales of products for apparel and industrial April 2011, Toray Group initiated a new three-year medium-term applications in the Fibers & Textiles segment, and efforts to in- management program, Project AP-G 2013, under which we will crease sales of products for aircraft, environment and energy- build on our achievements in previous medium-term manage- related applications, especially in the Carbon Fiber Composite ment programs. Toray Group is moving to a new growth track Materials segment. by adopting more proactive management while maintaining our Net sales increased by 3.2% year on year to ¥1,588.6 billion, commitment to relentless reform. operating income by 7.6% to ¥107.7 billion and net income by 10.9% to ¥64.2 billion. We set new records for both operating Record income despite challenging business income and net income. conditions The operating income ratio for the year under review was Despite continuing uncertainty in the business environment, we 6.8%, 0.3 points over the previous year’s figure. ROA reached have no intention of changing the direction of our growth strategy. 6.8% and ROE was 10.5%. “ Toray Group achieved record earnings in fiscal 2011, despite the negative impact of economic crises, ” natural disasters and other events. 18
Consolidated Financial Highlights Toray Industries, Inc. and Consolidated Subsidiaries Years ended March 31 Thousands of Millions of yen U.S. dollars 2012 2011 2010 2009 2008 2012 For the year: Net sales ¥1,588,604 ¥1,539,693 ¥1,359,631 ¥1,471,561 ¥1,649,670 $19,373,220 Operating income 107,721 100,087 40,107 36,006 103,429 1,313,671 Net (loss) income 64,218 57,925 (14,158) (16,326) 48,069 783,146 Cash flows from operating activities 104,410 129,214 166,215 38,447 110,367 1,273,294 Cash flows used in investing activities (104,002) (50,734) (121,723) (113,373) (164,151) (1,268,317) Free cash flows 408 78,480 44,492 (74,926) (53,784) 4,976 At year-end: Total assets ¥ 1,581,501 ¥1,567,470 ¥1,556,796 ¥1,523,603 ¥1,698,226 $19,286,598 Net assets 674,149 640,970 518,216 512,610 642,159 8,221,330 Per share of common stock (in yen and U.S. dollars): Net (loss) income: Basic ¥ 39.41 ¥ 36.41 ¥ (10.12) ¥ (11.66) ¥ 34.34 $ 0.48 Diluted 37.46 34.43 — — — 0.46 Cash dividends 10.00 7.50 5.00 7.50 10.00 0.12 Net assets 384.90 363.90 336.65 335.04 423.78 4.69 Ratios: Operating income to net sales 6.8% 6.5% 2.9% 2.4% 6.3% Equity ratio 39.7% 37.8% 30.3% 30.8% 34.9% ROA 6.8% 6.4% 2.6% 2.2% 6.1% ROE 10.5% 10.9% (3.0)% (3.1)% 8.1% Debt/equity ratio (times) 0.77 0.83 1.34 1.42 1.00 Note: U.S. dollar amounts have been converted from yen at the exchange rate of ¥82 = US$1, the approximate exchange rate prevailing on March 31, 2012. Net Sales Operating Income and Net (Loss) Income Cash Flows Operating Income to Net Sales (Billions of yen) (Billions of yen) (%) (Billions of yen) (Billions of yen) 2,000 140 7 70 200 60 150 120 6 50 1,500 100 100 5 40 50 80 4 30 1,000 0 60 3 20 -50 10 40 2 500 -100 0 20 1 -150 -10 0 0 0 -20 -200 Mar/ ‘08 ‘09 ‘10 ‘11 ‘12 ‘13 Mar/ ‘08 ‘09 ‘10 ‘11 ‘12 ‘13 Mar/ ‘08 ‘09 ‘10 ‘11 ‘12 ‘13 Mar/ ‘08 ‘09 ‘10 ‘11 ‘12 (Forecast) (Forecast) (Forecast) n Operating income (left) n Cash flows from operating activities l Operating income to net sales (right) n Cash flows used in investing activities l Free cash flows Note: Forecast for year ended March 31, 2013, announced on August 6, 2012. 19
To Toray Stockholders and Investors Total assets as of March 31, 2012 were ¥1,581.5 billion, source and energy problems, and contribute to the creation of a similar to the position at the end of the previous fiscal year. The sustainable, low-carbon society. Toray is already the world’s No. stockholders’ equity ratio rose by 1.9 points to 39.7%. We in- 1 manufacturer of carbon fiber composite materials, and we are creased the annual dividend by ¥2.5 to ¥10 per share. also expanding our water treatment membrane business with the aim of consolidating our leadership in that area as well. In addition, we are determined to establish Toray as No. 1 in the Pleasing progress under Project AP-G 2013 world in other priority areas, such as battery materials and bio- The key principles of Project AP-G 2013 are to expand business- mass materials. es in growth business fields and growth regions, and to estab- Sales from Green Innovation Businesses amounted to ¥428.2 lish a robust business footing by cost reductions. Activities that billion in fiscal 2011. We are now progressing steadily toward would yield major benefits on a group basis will be implement- our goal of ¥500 billion in fiscal 2013 (ending March 2014). We ed as group-wide projects. These are Green Innovation Business aim to increase sales to ¥1,000 billion in the period up to 2020. Expansion, Asia and Emerging Country Business Expansion and Achievements in priority fields in fiscal 2011 are outlined below. Total Cost Reduction. We plan to invest a cumulative total of ¥350 billion in plant • Carbon fiber composite materials: We decided to increase carbon and facilities over a three-year period that began in fiscal 2011. fiber production capacity in four key locations—Japan, the United Two-thirds of that amount will be targeted toward investment States, France and the Republic of Korea. in growth, with Green Innovation Businesses receiving a 60% • Water treatment membranes: We won an order to supply reverse share. We also plan to allocate 50% of our investment to Asia. osmosis (RO) membranes in Singapore for Asia’s biggest seawater We will invest a cumulative total of ¥160 billion in research and desalination plant. development during the three-year period, with 50% of that • Battery materials: Toray Tonen Specialty Separator Godo Kaisha, amount devoted to R&D relating to Green Innovation. originally a joint venture company, became a wholly owned subsid- iary. Toray Battery Separator Film Co., Ltd. was established. Green Innovation Business Expansion Project • Biomass materials: We succeeded in creating a prototype for the Toray Group believes that the Green Innovation Business Ex- world’s first polyester fiber derived entirely from biomass materials pansion (GR) Project will increasingly support its efforts to find and signed a joint research agreement with Ajinomoto Co., Inc. for solutions for problems in the global environment, including re- bio-based nylon. Net Assets and Equity Ratio Cash Dividend Per Share “Project AP-G 2013” Financial Targets (Billions of yen) (%) (Yen) 800 40 10 Fiscal 2010 (Actual) Net sales 1,539.7 8 Foundation businesses 966.4 (63%) 600 30 Strategically expanding businesses and 573.3 (37%) Intensively developing and expanding businesses 6 Growth countries and regions 540.3 (35%) 400 20 Green innovation businesses 378.0 (25%) 4 Operating income 100.1 200 10 Operating income to net sales ratio 6.5% 2 ROA 6.4% ROE 10.9% 0 0 0 Mar/ ‘08 ‘09 ‘10 ‘11 ‘12 Mar/ ‘08 ‘09 ‘10 ‘11 ‘12 ‘13 Remarks (Fiscal 2013) (Forecast) Estimated exchange rate 80 yen / US$ ROA=Operating income / Total assets n Net assets (left) l Equity ratio (right) Estimated oil price 95 US$ / B(DUBAI FOB) ROE=Net income / Stockholders’ equity 20
Asia and Emerging Country Business Expansion Project build a high-level production system domestically. We believe Under the Asia and Emerging Country Business Expansion (AE) that the key to drive this project is strong links between our Project, we are working actively to expand our businesses in domestic production sites and production sites overseas. This Asia and emerging countries of other regions that promise sub- will further business expansion and strengthen our cost com- stantial economic growth in the future. petitiveness as a group. In fiscal 2011, sales from growth countries and regions were ¥560.1 billion, equivalent to 35% of total net sales. The goal Total Cost Reduction Project is ¥720 billion, or 40% of total net sales in fiscal 2013 (ending Since the Lehman shock, Toray Group has targeted cost reduc- March 2014) and a contribution to total net sales of 50% by tions in all areas of activity without exception. These efforts around 2020. Achievements in fiscal 2011 are outlined below. have reduced fixed costs and variable costs by a total of over ¥100.0 billion. • China: The establishment of a production facility for dialysis ma- We believe sustainable growth and development requires not chines was followed by a decision to build a new production facility only the implementation of growth strategies, such as the GR for dialyzers. We also strengthened our research and development Project and the AE Project, but also the maintenance of a robust facilities in Shanghai for segments other than Fibers & Textiles. business footing. As part of AP-G 2013, we are also implement- • The Republic of Korea: We decided to expand our production ca- ing the Total Cost Reduction (TC-II) Project, the aim of which is pacity for lithium-ion battery separators. Work also continued on the to strengthen our total cost competitiveness. The entire Toray construction of a new carbon fiber plant. Group is involved in this initiative, which we see as vital to our • Indonesia: We decided to commence a high-performance polypropyl- achievement of sustainable growth in the future. ene spunbond business for infant disposable diapers and commenced construction of a production facility. • Other emerging countries: We established an office in India and also decided to establish an operational base in Brazil. Besides the above, Toray Group is continuing to develop advanced materials and maintain its strength in production of high-value added products in Japan. To expand overseas busi- ness, it is important to promote technology development and (Billions of yen) Fiscal 2011 (Actual) Fiscal 2013 (Targets) 1,588.6 1,800.0 1,036.2 (65%) 1,000.0 (56%) 552.4 (35%) 800.0 (44%) 560.1 (35%) 720.0 (40%) 428.2 (27%) 500.0 (28%) 107.7 150.0 6.8% 8.3% 6.8% 8% 10.5% 11% ( ) Net sales ratio 21
To Toray Stockholders and Investors One of our goals under AP-G 2013 is to reduce variable launching the AP-G 2013 program. costs by more than 3% per year, a total saving of 10%, or ap- We believe that the most important priority for Toray Group, proximately ¥70 billion, over the three-year period. In fiscal as a manufacturer of raw materials, is the accumulation of tech- 2011, we achieved a year-on-year reduction of 3.6%, or ¥24.1 nology. The reverse osmosis (RO) membranes manufactured by billion. Controlling fixed costs during a business expansion Toray Group today are the result of efforts spanning more than phase requires appropriate scale management. Our goal is to four decades. The expansion of our carbon fiber business is the keep the rate of increase in fixed costs within the rate of in- result of 50 years of research. The development of revolutionary crease in marginal profit. In fiscal 2011, we reduced fixed costs new materials is not something that can be achieved overnight. by ¥14.3 billion compared with the budgeted level. Toray Group is determined to maintain its position as one of the world’s leading raw material manufacturers by basing its management on perspectives that extend 10 or 20 years into AP-Growth Toray 2020—Management based the future. on long-term perspectives Fiscal 2011 brought a variety of environmental changes that had significant implications for the management of our business ac- Enriching society through the creation of tivities. However, an analysis of the long-term future outlook in- innovative materials dicates that world population will continue to increase, and that Toray Group aims to provide high value to all of its stakeholders there will be continued growth in emerging countries in Asia and through the sustainable expansion of its earnings, while also other regions. We are also certain that there will be an increasing working actively to contribute to social progress and prosperity need for action to deal with global environmental problems and and environmental preservation and harmony. meet needs in other key areas, such as food, water and energy. The world is seeking fundamental changes and innovation In February 2011, we formulated AP-Growth Toray 2020, in our approaches to environmental problems and problems our long-term corporate vision for the next 10 years. We aim relating to resources and energy. As one of the world’s leading to achieve net sales of ¥3,000 billion and operating income raw material manufacturers, Toray Group is determined to con- of ¥300 billion by around 2020 through global growth based tribute to the creation of an enriched society and improvement driven by innovation in the field of advanced materials and in the quality of life through the continuing development of Green Innovation Businesses. In fiscal 2011, we took the new technology and materials. We look forward to the continu- first step toward the realization of this long-term vision by ing support of our stockholders and investors. July 2012 President Image of Financial Indicators (Billions of yen) Around 2015 Around 2020 (Vision) (Vision) Net sales 2,000 3,000 Growth countries and regions 900 (45%) 1,500 (50%) Green innovation businesses 600 (30%) 1,000 (33%) Operating income 180 300 ( ) Net sales ratio 22
Toray’s Global Operations Share it... 23
With strategic presence and advanced technology, growing with communities Toray Group’s global production began to expand in 1963 with the commencement of fiber and textile production in Thailand. In a half-century, our overseas activities have evolved into a network spanning 23 countries and regions. Today, our overseas production ratios are 59% for fibers and textiles and 77% for films. In total, overseas business activities account for 45% of Toray Group net sales. 22,948 overseas employees Toray Group has 40,227 employees, of whom 22,948, or 57%, work overseas. Skilled people recruited in various countries and regions make an important contribution to Toray’s business activities. 24
50 years of global involvement and evolution Toray Group has expanded overseas in three phases. In 1956, we invested in a Hong Kong trading company, and in 1963 commenced fiber and textile production in Thailand. Our main goal was to capture demand for fibers and textiles in developing countries, and to establish bases for exporting to Europe and North America. The next phase, in the 1980s set up additional businesses overseas, especially in Europe and North America, through acquisitions and 45% other methods. We shifted to local production of products including carbon fibers in France and film products in the United States and France. Then, in the 1990s, we began a significant expansion into China. We es- tablished integrated production facilities in Nantong for the polymerization, spinning, weaving and dyeing of polyester fibers. In the Republic of Korea, we acquired the fiber and film operations of the Saehan Group and added electronic materials and other products to their line-up. Gradually, we moved into production of water treatment membranes and medical equipment in China and will move into carbon fibers in the Republic of Korea. We are also considering production operations in India and Brazil. Toray Group’s global 14% expansion has now entered a new phase, in which powerful economic n Japan growth in Asian countries and emerging economies is a major component of the Group’s expansion. n China n Other Asia 18% 55% n Europe, North America, Broad management resources bring key advantages etc. We have the ability to supply products of high quality made to Toray stan- 13% dards from any plant, all over the world. This network also brings flexibility to cope with currency fluctuations, supply-demand trends and effects from natural disasters. Products are manufactured in the most competitive loca- Regional Contributions to tions and moved between locations to ensure that no sales opportunity is Net Sales in Fiscal 2011 missed. By minimizing the impact of economic flux, Toray Group maximizes In fiscal 2011, overseas sales were the unique advantages it has gained through global business expansion. ¥712.4 billion, or 45% of total sales. As a manufacturer in the raw materials industry, Toray Group accumulates its We use all of the Group’s resources expertise and technology in its plants. For this reason, our basic policy on global and capabilities, such as extensive expansion is that once established, a plant should operate over the medium- to management resources and our long-term, working together with its local community to achieve mutual growth overseas infrastructure, to drive the and success. Over 50 years, Toray Group has built a network of plants, facilities expansion of our overseas business. and human talent around the world, together with invisible resources in the form of management know-how specific to each region. These assets give us important advantages in future business expansion. Broad expertise backed by experience is also the key to rapid production start up at overseas locations with different legal systems and cultural environments. Our current focus is the expansion of business activities in Asia and emerging economies. The efficient use of management resources will drive this process and enable rapid progress. Expanding global production in every business segment Toray Group is globalizing production at optimal sites for each product. Today, we are active in 23 countries and regions. We have established manufacturing sites for staple fibers, filament yarns, and spun yarn, woven fabrics, dyed prod- ucts and garments, especially in China and ASEAN countries. We also manu- facture fibers and textiles for airbags in Thailand, the Czech Republic and China. Other examples of growing global activities include the manufacture of suede-texture artificial leather for use in car interiors in Italy and polypro- pylene spunbond for disposable diapers in the Republic of Korea and China. In the area of plastics and chemicals, we manufacture plastic resins and films at overseas sites, especially in China, the Republic of Korea, ASEAN countries and other Asian locations. In addition, we have established plants 25
for PET film and other products in France and the United States as part of our global supply network. We anticipate demand growth for carbon fiber, and in addition to our existing plants in Japan, the United States and France, we also plan to com- mence production at a new facility in the Republic of Korea in January 2013. By creating this production structure based in four countries, we aim to achieve further expansion in this business area. Toray is also expanding overseas in the environment and engineering seg- ment. In addition to our existing production site for water treatment membranes in the United States, we commenced production at a facility in China in 2011. Major global expansion initiatives in fiscal 2011 Trends in Net Sales in Growth Countries and Regions Rapid economic growth in the ASEAN region has been paralleled by dramatic growth in sales of disposable diapers. Determined to capture this demand, in (Billions of yen) 3,000 3,000.0 2011 Toray established P.T. Toray Polytech Jakarta (TPJ) in Indonesia to manu- facture high-performance polypropylene non-woven fabric (PP spunbond), for disposable diapers. TPJ aims to start annual production of around 20,000 tons in June 2013, boosting our total PP spunbond supply capacity, with our existing 2,000.0 facilities in China and the Republic of Korea, to around 121,000 tons per year. 2,000 1,800.0 We are also expanding carbon fiber production in Japan, the United 1,539.7 1,588.6 States, France and the Republic of Korea. The annual capacity of Toray Group 1,500.0 is currently 17,900 tons. By March 2015, we will expand our total capacity, 1,075.4 including facilities now being built in Japan and the Republic of Korea, to 1,000 27,100 tons. This will enhance our ability to supply high-quality, high-grade 900.0 carbon fiber reliably to customers worldwide. 720.0 540.3 560.1 Improvements to healthcare systems and other changes are raising de- mand for dialysis machines and dialyzers in China. In June 2011, Toray and 251.5 0 Qingdao Jifa Group Co., Ltd. established Toray Medical (Qingdao) Co., Ltd. FY FY FY FY Around Around (TMQ), which plans to start manufacturing dialysis machines in the first half ‘00 ‘10 ‘11 ‘13 ‘15 ‘20 (Actual) (Actual) (Actual) (Target) (Vision) (Vision) of 2012 and dialyzers in the second half of 2014. ■■ Total net sales ■ Growth countries and regions (Asia and other regions) Sales from growth markets—rising to 40% by fiscal 2013 Toray Group has switched to a more aggressive management stance under its medium-term management program, Project AP-G 2013. In line with our basic strategy under this program, we are making cross-organizational efforts to de- velop our business activities in countries and regions with high growth poten- tial through the Asia and Emerging Country Business Expansion (AE) Project. The following four priority measures have been adopted for this project. ●W e will develop and supply products and materials for specific needs of Asian markets and emerging countries, building up our marketing to ensure market penetration. ● We will reinforce production infrastructure at existing sites and new sites. We will also enhance regional technical service. ●W e will make optimal use of existing management resources, includ- ing production and sales facilities. We will also use various methods, including alliances with leading local companies, to expand our business activities over a short timeframe. ● We will dynamically expand business activities, especially in the area of advanced materials, to meet strengthening demand from growing wealthy and middle-class populations. Toray Group aims to increase sales from growth business fields and re- gions, including emerging countries in Asia and other regions, from approxi- mately ¥560 billion, or 35% of total net sales, in the fiscal 2011 to ¥720 billion, equivalent to 40% of total net sales, in fiscal 2013. 26
Built-in Immunity to Exchange Rates Toray Group worldwide group-level business structure strategically minimizes exposure to the effects of exchange rate fluctuations. Toray’s products anywhere in the world are backed by Toray technology and Toray quality. During Thailand’s flooding in October 2011, we continued to supply customers by sourcing products from other Toray Group plants. Made in TORAY 27
Toray Group Segments Business Categories Segments Foundation Businesses Fibers & Textiles Net Sales Ratio 65.3% Plastics & Chemicals Operating Income Ratio 57.2% Strategically Expanding IT-related Products Businesses Realize it... Net Sales Ratio 19.7% Carbon Fiber Composite Materials Operating Income Ratio 33.2% Intensively Developing and Environment & Engineering Expanding Businesses Net Sales Ratio 14.2% Life Science Operating Income Ratio 8.5% Note: Excludes other businesses, equivalent to ¥13.3 billion (0.8%) in net sales and ¥1.3 billion 28 (1.1%) in operating income, and adjustment of operating income of –¥19.4 billion.
Main Products Application Examples Filament yarns, staple fibers, and woven and knit- • Women’s and men’s clothes (coats: man-made suede, dress shirts: polyester-cotton blended fabric, stock- ted fabrics of nylon, polyester and acrylic fibers, ings: nylon fiber, apparel products, swimwear) etc.; non-woven fabrics, man-made suede and • Automobiles (car seats: polyester fiber, airbags: nylon fiber, seatbelts: polyester fiber) apparel products • Sportswear • Furniture & interior (sofas: man-made suede, carpets: BCF nylon, curtains: halogen-free, flame retardant materials) • Disposable diapers: polypropylene filament yarn non-woven fabric • Tents: polyester fiber Nylon, ABS, PBT, PPS and other resins and molded • Automobiles (radiator tanks: nylon resin, intake manifold: nylon resin, connectors: PBT resin, capacitor products, polyolefin foam; polyester, polypropylene, for hybrid cars: polypropylene film) PPS and other films and processed film products; raw • Home appliances (housing for washing machines, vacuum cleaners, air conditioners: ABS resin) materials for synthetic fibers and other plastics; zeo- • Power tools (circular tools housing: nylon resin) lite catalysts; fine chemicals for pharmaceuticals and • Helmets (nylon resin) agrochemicals; veterinary medicine (excludes film • Solar battery panels (PET film) • Veterinary medicine (for dogs and cats) and resin covered in IT-related Products segment) • Potato chip bags (polypropylene film) • Flat panel display televisions (PET film, PDP) Films and plastic products for information and • Flat panel display televisions (PET film, PDP rear panel pastes, LCD color filter manufacturing equipment) telecommunications related products; materials • PCs (circuit materials, PET film, polyimide coatings) for electronic circuits and semiconductors; color • Cellular phones (color filters, LCP resin, circuit materials, PET film) filters for LCDs and related materials and equip- • Printing (waterless printing plates, relief printing on resins, printing equipment) ment; materials for plasma display panels; magnetic • Digital video camera recording film (PET film) recording materials; graphic materials and related • In-vehicle multimedia LANs (optical fiber) equipment • Semiconductors (semiconductor coating materials) Carbon fibers, carbon fiber composite materials and • Aircraft structure (carbon fiber composite materials) their molded products • Bridge pier reinforcement (carbon fiber woven fabrics) • PC chassis (carbon fiber molded products) • Wind-power generator blades (carbon fibers) • Marine vessels (carbon fibers) • Industrial equipment materials (carbon fiber, carbon fiber composite materials) Comprehensive engineering; condominiums; in- • Seawater desalination facilities (water treatment membranes and equipment) dustrial equipment and machinery; environment- • Sewage and waste-water treatment facilities (water treatment membranes and equipment) related equipment; water treatment membranes • Condominiums and related equipment; materials for housing, • Housing (wall siding for houses, interior materials for buildings) building and civil engineering • Plants and manufacturing facilities (comprehensive engineering services) Pharmaceuticals and medical products; analysis, • Pharmaceuticals (natural interferon-beta preparation, prostacyclin, antipruritus drug) physical evaluation and research services • Medical treatment devices (hemodialyzers, artificial dialyzer and equipment) • Physical analytical services 29
Toray Group Segments Foundation Business Fibers & Textiles (Billions of yen) Fiscal 2010 2011 Changes 2012 Forecast Net sales 584.1 638.4 +9.3% 680.0 Operating income 32.4 45.3 +39.7% 49.0 Fiscal 2012 forecasts announced on Aug. 6, 2012. ROA: 10.9% 584.1 638.4 45.3 Operating income to net sales: 7.1% 32.4 Capital expenditures: ¥21.3 billion ■ Net sales ■ Operating income FY FY FY FY 2010 2011 2010 2011 TOPICS Summary of consolidated financial results for fiscal 2011 Expanding Green Innovation (Ended March 31, 2012) Businesses in the field of Domestic sales of products for apparel applications benefited from strong demand Fibers & Textiles for materials used in functional innerwear. In the area of industrial applications, sales of materials for automotive applications rallied in the second half in response to the One of the priority themes identified in our cur- post-earthquake recovery of automobile manufacturers’ production operations. rent medium-term management program, AP-G Overseas, the floods in Thailand affected both production and sales. How- 2013, is the expansion of our Green Innovation ever, trends in sales of products for both apparel and industrial applications Businesses. In June 2011 we took an important were generally firm, thanks to efforts to expand sales and shift to high value- step toward the expansion of Green Innovation added products in a number of areas. They included polyester filament yarn, Businesses in the Fibers & Textiles segment by staple fibers and textiles for apparel applications in China and ASEAN countries, establishing the Fibers & Textiles Green Innova- polypropylene (PP) spunbond for disposable diapers in the Republic of Korea tion Business Planning Department to formu- and China, textiles for airbag applications in Thailand and the Czech Republic late growth strategies and business plans, facili- and suede-texture artificial leather in Italy. tate commercialization and provide support for Net sales for the Fibers & Textiles segment in fiscal 2011 increased by 9.3% the Green Innovation Businesses that we are year on year to ¥638.4 billion. Operating income was 39.7% higher at ¥45.3 billion. currently developing in each business division. Toray is working to expand business that Outlook for fiscal 2012 contributes to energy conservation, such as materials designed for warmth or coolness, and Within Japan, we expect demand for materials used in industrial applications to biomass-derived fibers. We have also acceler- remain generally strong, reflecting the recovery of automobile production and ated the development and commercialization demand from reconstruction in the wake of the Great East Japan Earthquake. of new products. Green Innovation Businesses However, overall market conditions for apparel applications are likely to be in- in the Fibers & Textiles segment contributed net creasingly challenging because of weak consumer spending, the persistent yen sales of ¥67.9 billion in fiscal 2010 and ¥82.5 appreciation, and major fluctuations in raw material and fuel prices. billion in fiscal 2011. Our target for fiscal 2013 Overseas, demand can be expected to remain on an expansionary trend in (the year ending March 2014), the final year of emerging countries. In addition to the stagnation of European markets, howev- AP-G 2013, is ¥93.0 billion. er, there is also concern that customers will delay purchasing decisions because of sharp fluctuations in raw material and fuel prices, and we therefore expect business conditions to remain generally difficult. In this business environment, we will implement measures to secure ex- pected income from the Fibers & Textiles segment as a Foundation Business and to expand business globally. We will work dynamically to capture demand in China and other growth regions, also in growth business fields, such as automo- tive applications, disposable diapers and environment-related fields. We will also aim to strengthen and expand our garment business, which is structured around a planning and proposal model based on the development of new materials. 30
Foundation Business Plastics & Chemicals (Billions of yen) Fiscal 2010 2011 Changes 2012 Forecast Net sales 382.3 397.8 +4.1% 430.0 Operating income 27.1 27.4 +1.0% 27.0 Fiscal 2012 forecasts announced on Aug. 6, 2012. ROA: 6.6% 382.3 397.8 Operating income to net sales: 6.9% 27.1 27.4 Capital expenditures: ¥23.1 billion ■ Net sales ■ Operating income FY FY FY FY 2010 2011 2010 2011 TOPICS Summary of consolidated financial results for fiscal 2011 Expansion of domestic (Ended March 31, 2012) Production capacity for PPS Trends in the domestic market were affected by the Great East Japan Earth- resin Torelina® quake, which caused a volume decline in sales of plastic resins for automotive applications. However, a recovery emerged from the second quarter. In overseas Toray has decided to increase its production markets, the global economic slowdown was reflected in sluggish demand, es- capacity for the polyphenylene sulfide (PPS) pecially for general-purpose ABS resins. resin Torelina ®. Capacity for an additional In the films business, domestic demand for both industrial and packaging 5,000 tons per year will be added at the applications remained generally firm during the first two quarters. Overseas, Tokai Plant in Japan. When the new facilities sales were higher in the United States, Europe and Asia. However, domestic and become operational in January 2013, total overseas demand waned, intensifying price competition from the third quarter PPS resin production capacity will increase to onwards under the impact of a global economic slowdown. 19,000 tons per annum. Net sales for the Plastics & Chemicals segment, a Foundation Business, PPS resin is a super engineering plastic amounted to ¥397.8 billion, a year-on-year increase of 4.1%. Operating income with a range of excellent characteristics, in- increased by 1.0% to ¥27.4 billion. cluding resistance to heat and chemicals, me- chanical strength and fire resistance. It is used Outlook for fiscal 2012 in an expanding assortment of products, such as automotive electrical components, electri- Raw material and fuel prices are expected to fluctuate wildly, and the shift cal and electronic devices, office automation to overseas production by domestic customers of our products will continue. equipment and housing parts. World demand However, we anticipate that market conditions will improve thanks to the post- for PPS resin compounds is estimated at earthquake recovery of automotive production, combined with demand growth around 80,000 tons per year and is expected in China, the ASEAN region and emerging countries. to grow by 8% per annum. In this business environment, in the plastic resins business, we anticipate in- Toray’s comprehensive involvement in PPS creased sales of products for automotive applications and further growth in sales manufacturing encompasses not only PPS in China, the ASEAN region and emerging countries. We aim to maintain and resin compounds, but also films and fibers. In expand the spreads between selling prices and fuel and raw material prices by terms of business scale, we are number one in quickly passing on increased fuel and raw material costs quickly to selling prices. the world. We will continue to consider further In the films business, there is strong pressure from customers to reduce prices. increases in production capacity to keep pace We are determined to expand sales of high value-added products for industrial with expanding demand for PPS resins. and packaging applications. 31
Toray Group Segments Strategically Expanding Business IT-related Products (Billions of yen) Fiscal 2010 2011 Changes 2012 Forecast Net sales 262.0 243.4 -7.1% 270.0 Operating income 42.2 34.5 -18.3% 31.0 Fiscal 2012 forecasts announced on Aug. 6, 2012. ROA: 10.4% 262.0 243.4 Operating income to net sales: 14.2% 42.2 34.5 Capital expenditures: ¥27.2 billion ■ Net sales ■ Operating income FY FY FY FY 2010 2011 2010 2011 TOPICS Summary of consolidated financial results for fiscal 2011 New production facility for (Ended March 31, 2012) surface protection film Demand for materials for use in small and medium-size flat panel displays established in Taiwan (FPDs) for smartphones and other devices remained firm throughout the pe- riod under review. However, a slump in the market for flat-screen televisions In May 2011, Toray Advanced Film Co., Ltd. resulted in panel production cutbacks. This was reflected in slower demand for decided to establish Toray Advanced Film Ka- products used in LCD and plasma televisions, including films and processed ohsiung Co., Ltd. in Kaohsiung City, Taiwan, and film products. to build a new production facility for Toretec® Net sales for the IT-related Products segment in fiscal 2011 were 7.1% low- self-adhesive surface protection film. Produc- er year on year at ¥243.4 billion, while operating income declined by 18.3% to tion at the new facility will commence in Janu- ¥34.5 billion. ary 2013. The company plans to expand capac- ity progressively until it reaches 17,000 tons by Sub-segment (Billions of yen) the summer of 2013. Fiscal 2010 2011 Changes Toretec® is widely used as a process film Display Materials 105.6 90.3 -14% in the manufacture of LCD optical films and as Electronic components, semiconductors, a surface protection film for plastic boards. The 92.7 86.2 -7% electric circuit materials decision to establish a new production facility Data storage materials 32.8 34.1 +4% in Taiwan was taken in response to requests Equipment, others 30.9 32.8 +6% from major manufacturers in Taiwan, which has the biggest share of the world market for Outlook for fiscal 2012 light guide plates. It was also prompted by the improvement of export competitiveness fol- Production cutbacks by panel manufacturers are expected to give way to a recovery lowing the signing of an economic cooperation that should bring a gradual improvement in demand for materials for large FPDs in framework agreement (ECFA) between Taiwan the first half of the year. A return to demand growth is expected to emerge in the and China. second half, but customers will exert increasing downward pressure on prices. We anticipate continued growth in demand for smartphone- related materials. Our priorities in this environment will be the ex- pansion of sales of films and processed film products for FDP applications and electronic components, the development of high value-added products and the im- provement of cost competitiveness. We will also target increased sales of other products, including semiconduc- tor materials and printing materials. 32
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