Special特 集Feature2

Toyota Industries’ Textile Machinery
Winning Trust Spanning Generations

2—Contributing to Customers’ Businesses with Advanced Technologies and Services—

Toyota Industries’ Air-Jet Looms Undergoing
Evolution Together with Customers Worldwide

in the Textile Industry That Drives Pakistan’s Economy
Established in 1951, Nishat Mills, Ltd is one of the largest textile companies in Pakistan and has since
become the country’s representative conglomerate, with its businesses encompassing not only textiles, its
founding business, but also banking and insurance. Since Nishat Mills’ establishment, Toyota Industries has
been involved in an excellent business relationship with the company across generations as a main supplierof spinning and weaving machinery.
For this special feature, we spoke with Mr. Muhammad Mansha, Chairman of the Nishat Group, about histhoughts on Toyota Industries’ textile machinery and the long-standing history between the two companies.

Toyota Industries Providing Support
since Our Foundation

JAT810, Toyota Industries’ latest air-jet loom
新型エアジェット織機 JAT810

Sakichi Toyoda, the founder of Toyota Industries Corporation, devoted his passion to the invention of automaticlooms. Inheriting such dedication, our air-jet looms have evolved into a product that incorporates a number ofadvanced technologies and continue to claim the No. 1 global market share*.
On the back of economic expansion in such emerging countries as China, India and ASEAN nations, thegrowth rate of the textile industry is expected to surpass the global population growth rate. As such, weanticipate our air-jet looms will provide vital support to the development of the textile industry.
Toyota Industries’ air-jet looms are capable of weaving a vast range of products, including standard fabrics
for shirts and sheets; comfortable denim with extensive design possibilities; soft and exceptionally absorbent
high-end towels; and light and highly functional sportswear featuring excellent breathability and quick drying.
What’s more, our air-jet looms can be used to manufacture such industrial products as materials for electroniccomponents. These expansive capabilities are highly acclaimed by numerous customers worldwide.
In this special feature, we look back on how we have forged deep relationships with our customers and how
our air-jet looms have become their weaving machine of choice.
* Survey by Toyota Industries Corporation

Nishat Mills began its remarkable journey when my father
established a small spinningmill in 1951 in Pakistan. With
the purchase of shuttle looms
from Toyota Industries(hereafter, Toyota) in the mid1950s, the company entered
the weaving business. In
1962, we established aspinning mill in what was thenEast Pakistan (currentlyBangladesh) and installed
Toyota’s spinning machinery.
Mr. Muhammad Mansha
Chairman of MCB Bank;
After inheriting the business
Chairman of Nishat Group
from my father, we introduced
Toyota’s RY spinning frames in1981 and from there we dramatically expanded our spinningbusiness. In the mid-1990s, we constructed a dyeing andfinishing plant, in which we subsequently established theweaving division in 2003, and purchased Toyota’s JAT710
air-jet loom for the first time. Since then, our textile businessreally took off.
From the very beginning of our existence until now,
Toyota has always been there for us, supporting our growthwith their technologies and services. What is remarkableabout Toyota is that they not only offer state-of-the-art
machinery but also provide our factory operators withmeticulous guidance on the optimum methods of operationand maintenance specifically suited to our business throughclose observation of the operational status at our factories
by Toyota’s developers and service staff. With this kind ofsupport, we have been able to manufacture products byeliciting the maximum performance of the machines at alltimes. When machines are not working well, we can dependon Toyota to offer quick and comprehensive maintenancesupport. If improvements are required, they make sure thesewill be reflected in the development of the successor model.
In these ways and others, we have absolute faith in theirsincerity and integrity.

Contributing to the Development of the Textile
Industry with the Latest Air-Jet Looms
In 2014, we completed a new textile mill, which features thelatest JAT810 air-jet looms. Under the concept of the world’s
best energy-saving textile mill, the factory is fitted with lighting
fixtures, air conditioners and other equipment that incorporate
the latest advancements in environmental technologies. Webelieve it’s one of the most environmentally conscious textile
mills not only in Pakistan but also throughout the world.
Needless to say, we demanded extremely strict environmentaln Toyota Industries’ After-Sales Service Network (Overseas Service Centers)n Air-Jet Loom Market Share (2013)
Total market size and share:
Survey by Toyota Industries Corporationn Textile Product Demand and Global Population Growth(Thousand tons)(Million tons)(Billion persons)(Billion persons)880

l 1 South Korea
l 2 China(Shanghai, Shaoxing, Wujiang,Jinan, Changzhou, Lanxi, Tianjin)

6608ToyotaIndustries
Total market size

25,000 units

31%

440220(Year)

1995

2000

2005

2010

2012

(Year)

nn Textile product demand (Source: TEXTILE HANDBOOK 2014)
nn Global population (Source: Population estimates by Japan’s Statistics Bureau,
Ministry of Internal Affairs and Communications)Toyota Industries Report 201426l 3 Taiwan

9l 4 Thailand

34l 5 Indonesia
l 6 India

5020

1

7010l 7 Pakistan
l 8 Switzerlandl 9 U.S.A.
l 10 Brazil

21

performance of weaving machines because they will play acentral role at this factory. After closely comparing Toyota’s
and their competitors’ products, we decided to install
Toyota’s JAT810 air-jet looms. We know we made the rightdecision because the textile mill as a whole has been able tosave energy by up to 20%.
Although Pakistan has been plagued with unstable
power supplies, as the country’s representative
conglomerate the Nishat Group is tackling the problem headon. We are striving to take the initiative in energy savings,
thus contributing to the development of our country’sindustries.
My son, Umer Mansha, has now taken over the Nishat
Group’s textile business. I hope he will continue to cherishand carry on the relationship of trust with Toyota well into

the future, just as I did when I
succeeded my father.
I have a special affinity for thetextile business, which
represents the roots of theNishat Group. Likewise,
Toyota began its corporate
journey with the textile
machinery business. I sincerely
hope the two companies willcontinue to grow while
contributing to thedevelopment of society.

Toyota Industries Supporting a Cutting-Edge Businessin Taiwan’s Electronics Industry that Contributes to the Global EconomyMr. Umer Mansha
CEO of Nishat Mills, Ltd

The electronics industry accounts for a large portion of the Taiwanese economy.
Nan Ya Plastics Corporation (NPC) is a member of the Formosa Plastics Group, one of the largest
conglomerates in Taiwan, and engages in the manufacture of such products as cloths for printed circuitboards of mobile phones and PCs as well as glass fibers for weaving these cloths. As one of the world’s mostprominent players in the glass fiber field, NPC is a significant contributor to the electronics industry in Taiwan
and operates more than 3,000 air-jet looms made by Toyota Industries.
Mr. William Wong, Chairman of the Formosa Plastics Group, to which NPC belongs, talked about the role ToyotaIndustries’ air-jet looms are playing in the manufacture of high value-added products for the electronics industry.

Air-Jet Looms Suitable for
the Production of High-Quality Cloths for
Printed Circuit Boards

JAT810 air-jet looms in operation at Nishat Mills, Ltdn Excellent Energy-Saving Performance of JAT810 Air-Jet Loom
The most prominent feature of air-jet looms is to insert the weft yarn
at a high speed by injecting compressed air to weave fabrics. Thisis done using a large compressor, a process that requires thelargest amount of energy. Consequently, the key to energy savings
is how to minimize waste and efficiently insert weft yarn with littleair. In other words, using less air equals consuming less power.
Our JAT series of air-jet looms has consistently featured better airsaving performance that surpasses competitor products. For theJAT810, innovations were made to such devices as the sub-nozzle,
which injects air, and the air path. All these innovations and more
led to a yet another reduction of approximately 20% in air
consumption compared with the previous JAT710, also a highly
energy-saving model.

Toyota Industries Report 2014

Fulfilling Expectations throughEver-Evolving Machine Performance andSincerity of Toyota Staff
As smartphones and a growing variety of electronic devices
rapidly gain popularity, demand for electronic components is
exploding all over the world. In response, we need tomaximize the capabilities of weaving machinery in ouroperations. For us, it is of extreme importance that we
efficiently manufacture top-quality cloths.
Toyota’s air-jet looms constantly meet such exacting
demands at a high level while its service staff quickly arriven Various Products That Toyota Industries’ Air-Jet Looms Can Weaven Air Consumption Volume20%

reduction

20%

reduction

JAT610(1996–2003)

JAT710(2003–2013)

JAT810(2013–)(Survey by Toyota Industries Corporation)

22

The Formosa Plastics Groupwas established by my father,
Wang Yung-tsai, and his older
brother, Wang Yung-ching, toproduce polyvinyl chloride
products. It has grown into
one of the largest
conglomerates in Taiwan, withbusinesses encompassing
petrochemistry, electroniccomponents, medical care,education, transportation andMr. William Wong
Chairman of the Formosa Plastics Groupother areas.
Executive Board
Our business with Toyota
Photo courtesy
Industries (hereinafter, Toyota)of cnYES
began in the 1970s when
http://www.cnyes.com
Formosa Chemicals & Fiber
Corporation, one of the Formosa Plastics Group companies,
purchased spinning frames from Toyota. Formosa Chemicals& Fiber has been a continuous user of Toyota’s air-jet looms
as well since installing the machine’s very first generation.
Our relationship further expanded in 1994 when NPC,
which manufactures electronic components, introduced air-jet looms to weave glass fibers.
Compared with common clothing fabrics, printed circuitboard cloths made of glass fibers require extremely delicate
quality management because the tiniest defect, which is
unrecognizable to the naked eye, could possibly cause
malfunctions. Toyota’s air-jet looms come equipped withhighly sophisticated technologies, such as for realizing
gentle weft yarn insertion by reducing air pressure to injectyarn even during high-speed operations, enabling us tomeet such rigorous demands and weave high-quality cloths.
Valuing such strengths, we decided to switch from weaving
machinery produced by other manufacturers that we wereusing. Currently, we operate a total of more than 3,000
Toyota air-jet looms at our factories.

Shirt

Denim

TowelsPrinted circuit board

23

on the scene when we need them andmake necessary adjustments so that themachines will operate in optimalcondition. We believe Toyota’s attitude ofalways being sincere in meetingextremely severe requirements for quality
and productivity in the manufacture ofelectronic components is reflected in theproduct capabilities of its air-jet looms
and the level of its services.
Electronic components represent
one of Taiwan’s core industries, making
significant contributions to the global
economy. With Toyota as our essential
business partner, we intend to play acentral role in Taiwan’s progressively
growing electronics industry.

Nan Ya Plastics Corporation’s glass fibers

JAT710 air-jet looms in operation at Nan Ya Plastics

n History and Unit Sales of Our Air-Jet Looms(Units)
12,000n Future Development

Model namesJAT810
JAT710
JAT61010,000

JAT600
JAT500

8,000

JATJA

6,000

4,000

2,000

024(FY) 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14

Toyota Industries Report 2014

In addition to technologies accumulated
to date, we are tapping into the world’s
top-level sensor technologies andinformation processing technologies
developed by Switzerland-based Uster
Technologies AG, which became amember of the Toyota Industries Group in2012, in our efforts to create revolutionary
new products.
We are striving to further enhancecustomer trust by strengthening ourproducts along with honing our prompt
and meticulous service capabilities.