SpecialFeature

2

Roundtable Discussion

Aiming to Realize Both a Comfortable Vehicle
Interior and Energy Savings—Delivering Electric Compressors to Four Corners of the World—
Electric compressor seriesn What Is an Electric Compressor?
In a car air conditioner, a refrigerant (liquid) is cycled throughout an air-conditioning system in a repeated process of vaporization(evaporation), liquefaction and re-vaporization, and the vaporization heat generated during this process is used to keep thevehicle interior comfortable. The heart of a car air conditioner is the compressor. Unlike other types of compressors that derive
power from the engine, electric compressors draw power from the battery, allowing the air conditioner to run during an idling stopof HVs and other electric-powered vehicles.

As a leading manufacturer of car air-conditioning compressors, Toyota Industries develops electriccompressors for HVs, PHVs and other electric-powered vehicles that match the needs of customers.
We are making ongoing efforts to expand sales of electric compressors not only to Toyota Motor
Corporation (TMC) but also to automakers around the world.
In 2012, we commenced sales of the ESA34 electric compressor. In addition to such features asenhanced fuel efficiency and lighter weight, the new compressor makes it easier to mount in vehicles.
For this roundtable discussion, four key members of the development project respectively from thedevelopment, productionengineering, quality assurance
and manufacturing departments
got together to look back on thethree-year collaboration effort andtalked about the future of Toyota
Industries’ electric compressors.
HV: Hybrid vehicle
PHV: Plug-in hybrid vehicle
EV: Electric vehicle

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SpecialFeature◉ Electric Compressor SeriesVehicle Size20032005

Large class

2007
ES34

Medium class

ES272009
Significantly improved
quiet operation for
luxury vehicles

Smaller and lighter throughindustry-first integration of inverter

World’s first mass-produced
electric compressor

ES1420112013(Year)

ESA34

Easier to mount on vehicles byplacing inverter on the side

ESA27

Easier to mount on vehicles byplacing inverter on the side

2 Aiming to Realize Both a Comfortable Vehicle Interior and Energy Savings◉ Electric Compressor Sales(Thousand units)

Sales of electric-powered vehicles (HVs, PHVs, EVs) (CY)*

2,000
1,500
Unit sales of Toyota Industries’
electric compressors (FY)

1,000
500

Even smaller and lighter

Compact class

ES18

Receipt of SilverPrize in 2013 Aichi
Environmental Awards

Through the serialization of electric compressors, Toyota Industries realized reductions in size and weight as well as
higher operational efficiency. In recognition of their contribution to improving fuel efficiency of vehicles and reducing
CO2 emissions, Toyota Industries received the Silver Prize in the 2013 Aichi Environmental Awards.

0Ken Suito

Assistant General Manager,Engineering Office No. 3, Engineering
Department, Compressor Division

Takayuki NakaseGroup Manager, Electric AssemblyGroup, Assembly Production
Engineering Office, ProductionEngineering Department,Compressor Division

Product Strengths Incorporating
Technologies, Ingenuity and Teamwork
Suito: Let’s look back on the development phase. In theengine room where the car air-conditioning compressor ismounted, many other devices are also installed including
the engine. In recent years, more space must be set aside
in the engine room to ensure safety in the event of acollision, requiring compressors to be even smaller andlighter. On the other hand, an electric compressor must beequipped with a motor and an inverter that controls themotor’s revolutions, which makes the compressor bulkier.
To address such issues, we integrated the inverter with thecompressor and made the motor smaller. For the ESA34,
we changed the placement of the inverter to make it easier
to mount the compressor in a vehicle, thereby realizing amore compact, lighter-weight and more highly efficientcompressor that fully utilizes Toyota Industries’ longaccumulated technologies. One of our strengths, I believe,lies in the fact that we develop and produce motors andinverters in-house.
The ESA34 is also the world’s first electric compressor
to adopt a mechanism to control inner pressure of thecompressor, which contributes to further improving fueleconomy.
Abe: This mechanism is effective in attaining significant
fuel efficiency, but it is revolutionary in an unprecedented
way in other areas as well. Consequently, fully
understanding the development concept and functional
impact of the compressor was required in all phases fromdevelopment to manufacturing as well as thoroughly

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Toyota Industries Report 2013

Masashi Abe

Takashi WatanabeGroup Manager, Production Quality
Supervisor, Assembly Section,Group, Quality Assurance Office
Manufacturing Department No. 1,No. 2, Quality Assurance Department,Compressor Division
Compressor Division
Positions and departments as of March 31, 2013

analyzing and taking measures for every potential flaw ineach process. That’s why the relevant departments got
together and conducted meticulous discussions from theearliest phase of the development.
Suito: By gathering all related personnel from the relevant
departments from the very first phase of development forthese so-called conference room activities and sharing
information every step of the way, we were able to not only
realize speedier development but also ensure quality andproductivity.
With HVs, the running sound of the compressor tends
to be more noticeable than internal-combustion vehicles
because the engine stops rotating when the car comes toa stop. That makes quiet compressor operation all themore important, and the ESA34 displays its excellence interms of quietness. In this aspect as well, we fully leveraged
our long-standing technologies for quiet operation requiredfor compressors to be fitted in luxury vehicles.
Car air-conditioning compressors must operate undera variety of difficult conditions, including temperaturefluctuations, humidity, dust and vibrations. We believe thetrend toward electric-powered vehicles will continue toaccelerate, and we are undertaking our work with thepride that it is we who can assure the quality expected ofin-vehicle devices because we have been involved in carrelated businesses for a very long time.
Nakase: In the production engineering phase, we adopted
the shrink-fitting technique, which utilizes the difference
between heat-induced expansion and shrinkage to join
together two parts made of different metals. This requireda process of trial and error under various conditions,(CY/FY)

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

including sensitive temperature adjustments as well as
the thickness and shape of materials. In the end, wesucceeded by making use of the computer simulation
system produced internally.
Suito: These efforts led to a fewer number ofcomponents, which resulted in a reduction in production
processes. I believe it was a significant achievement that
we were able to contribute to cutting costs and making
the compressor lighter while at the same time attaining
better fuel economy.

Launch of Compact Production Line
Responsive to Fluctuations in ProductionVolume
Nakase: In addition to enhanced product appeal,establishing a production structure responsive tofluctuations in demand is equally important in recent years.
At Toyota Industries, we launched a more compact
production system that is one-third the size of
conventional production lines. This was the first endeavor
for the Compressor Division. We aimed to halve theproduction area allocated for each compressor unit andreduce the number of processes. To that end, we made a
prototype production line built to actual size andmethodically verified the positioning of workers andoperation efficiency in a real-time production setting.
Toyota Industries is working to prevent the outflow ofmanufacturing know-how by internalizing the design andproduction of such primary facilities as production
equipment and inspection devices. In order to realize thiscompact production line, it was necessary to review thesize of equipment and change work processes, but ourhard work paid off and we succeeded in creating theproduction line in-house.
Abe: Actually, obtaining pre-approval from automakers isrequired when we adopt a new production process orquality assurance method. To do so, we startedpreparations quite early on.
Nakase: For the creation of this compact production line,
we worked together on preparations transcending borders
among production engineering, quality assurance,
manufacturing and other relevant departments. In thisregard, I believe it was an excellent experience for all(Plan)
CY: calendar year ended Dec. 31; FY: fiscal year ended March 31 of the following year
* Survey by Toyota Industries Corporation

departments involved because we were able toconsolidate tasks and processes while ensuring a highstandard of quality.
Watanabe: This compact production line can be applied
to the manufacture of non-electric car air-conditioning
compressors as well. As such, we are proactively installing
the line at production sites outside Japan. In order tohandle future fluctuations in global demand, we areconfident this production line will exert its potential to thefull extent.

Dedicated Initiatives to Ensure High
Product Quality
Suito: Currently, companies are globalizing theirproduction activities and standardizing components. Thatmeans quality is all the more important. In the Engineering
Department, we have been engaging in new developmentchallenges while utilizing technologies accumulated in thedevelopment of car air-conditioning compressors forinternal-combustion vehicles. I believe each department
has been similarly making various efforts to ensure quality.
Watanabe: In the Manufacturing Department, we created
and will continue to upgrade a procedures manual thatspecifies how a single act or omission in a process will
have an impact on our customers and engage in daily
work accordingly. We also hold a meeting every morning.
This involves confirmation of the previous day’s issues,
no matter how minor they are, and immediate
implementation of countermeasures in cooperation
with personnel tasked with production engineering,quality assurance and equipment maintenance.
Abe: At the Quality Assurance Department, we faithfully
follow the concept of “jikoutei-kanketsu (build in quality
with ownership)” to incorporate quality in each process toensure that only the best-quality products are sent to thepost-processes. We believe everything we do both on theproduction floor and in our daily work is based on thispremise.
In fact, when it comes to quality, our compressors arehighly regarded by automakers not only in Japan but also
in the United States and Europe.
High product quality was not the only factor for
automakers in choosing our ESA34 electric compressor.

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SpecialFeature

Through a process inspection on the production floor, theyalso came to appreciate the ingenuity built into theproduction line, our thinking behind quality assurance andthe skill levels of our workers. I feel the trustworthiness of
our products is backed up by our track record that ourelectric compressors are fitted in every single Toyota HV.
Nakase: In the Production Engineering Department, weare striving to create an environment where employees in
the Compressor Division and the Electronics Division,
which engages in the development of inverters and othercomponents, share the same expertise in our efforts tofurther ensure product quality.
Abe: In my department, we are trying to raise the overall
skill levels of employees through a comprehensive training
program spanning from development to manufacture ofelectric compressors. Carrying out efforts in a holistic way
for one project deepens one’s knowledge and enables us
to gain a broader perspective, which I believe will lead tothe growth of our human resources.

2 Aiming to Realize Both a Comfortable Vehicle Interior and Energy Savings

accurately understanding and meeting the needs of bothautomakers and customers who drive their cars.
We will continue to devote our efforts toward
developing both hardware and software, working closelywith the Electronics Division and manufacturing production
equipment internally. Through such comprehensive
capabilities, we are confident that we can meet the various
needs of automakers while making a range of proposals.
We are determined to realize the continued
development of fuel-efficient and high-performance electriccompressors and contributing to customers’ businesses.
Nakase: In the Production Engineering Department,
I believe the launch of this compact production line enabled
us to accumulate know-how on how to respond tofluctuations in production units. So that we can more flexibly
respond to demand fluctuations on a global basis, we will
work to raise the potential of this compact production lineand proactively apply the know-how to production lines tobe set up in the future in and outside Japan.
Abe: No matter how diversified customer needs become,or no matter how much production units increase, for us
quality will always remain our lifeline. I consider it ourresponsibility to continue meeting the expectation ofcustomers while delivering high quality products.
Watanabe: As we expect the manufacture ofcompressors to keep increasing at production sitesaround the world, it is of the utmost importance that we
maintain the best quality regardless of where compressors
are produced. To do so, we are devoting efforts toward
the training of human resources for Group companies
outside Japan by designating production sites in Japan as
mother plants.
Suito: Today, members from each department involved in
the development of the new ESA34 electric compressor
got together to look back on the creative efforts and talkabout the future direction of compressors. I believe thisoccasion turned out to be a perfect opportunity to sharethe sense of fulfillment in creating a great product and tofurther motivate us to continue to offer even better
products for our customers.
In step with more widespread use of HVs and EVs,
we remain fully committed to helping to provide ourcustomers with an energy-efficient and comfortable
driving experience.

Fully Committed to Further Sales
Expansion
Suito: Since our mass-produced electric compressors
were fitted in Toyota HVs for the first time in the world in
2003, we have broadened our customer base ofautomakers and increased the number of vehicle models
installed with our products, which resulted in unit sales
growth all around the world. As we expand sales,
however, we must thoroughly meet the more diverse anddemanding needs of our customers. For example, there isparticularly strong demand for quiet operation amongJapanese automakers, while in the United Statesoutstanding operation of car air-conditioning compressors
under harsh conditions is expected due to the country’svastness. Meanwhile, Europe is the world’s mostdemanding region for excellent fuel economy. What’smore, paying close attention to the heating capabilities ofcar air conditioners is equally important for HVs, in which
the engine stops during an idling stop, as well as for EVs,
which are not equipped with an engine in the first place.
We are also expected to make use of eco-conscious
refrigerant from the standpoint of curbing global warming.
Being the world leader in unit sales of car airconditioning compressors* entails extensively and* Survey by Toyota Industries Corporation◉ Vehicles Equipped with Our Electric Compressors

BMWNon-Toyota

VehiclemodelsEstima HVHighlander HVToyota

VW

Renault

Daimler PorschePrius

For HVs

Renault RAV4-EV Nissan

Prius PHVFor PHVs and EVs

Harrier HV

Camry HVLexus LS600h

Prius
AlphardSAI

Aqua

Lexus ES

Yaris

AvalonLexus GS450h Crown HV Lexus HS250h Lexus RX

Lexus CT200h

Toyota Industries Report 2013

Promote sales
expansionFordPrius 24

HondaLexus IS

Fitted inall models