Does the Kobe Steel Scandal Affect My Organization?
By: Mary Dunham, ERAI, Inc.
ERAI has been contacted by several members concerned by the Kobe Steel scandal and the possible impact on their companies. This article will briefly discuss these issues.
Background
On October 8, 2017, Kobe Steel, Ltd. (hereafter called "Kobe") announced that it had learned through self-inspections and audits that its Aluminum & Copper Business, including group companies, had provided customers with products that did not comply with the agreed-upon product specifications, that data in inspection certificates had been improperly rewritten, and products were shipped as having met the specifications but did not. Kobe reported it also had violated statutory standards set up by the industry ministry
1 in addition to its failure to meet customer-agreed specifications and falsifying the certifications (hereafter called the "Misconduct"). It was discovered that in 2016, Kobe shipped products displaying the JIS mark (Japanese Industrial Standards) that did not meet JIS standards. Kobe initially reported that 525 companies had received products with falsified data.
At that time, in addition to the self-inspections already taking place in the company, Kobe created an Independent Investigation Committee (hereafter called "IIC") to investigate the misconduct. The IIC was comprised of lawyers who had no involvement with the investigation or interests in Kobe. The IIC Report was released on March 6, 2018 and found that the number of affected customers had risen to 688 and that the falsification of data had occurred over a much longer period of time, in some cases as early as the 1970s.
The 105-page report issued by the IIC discusses in depth the type(s) of Misconduct, the affected products, the period during which the Misconduct took place, and the people who were involved or knew about the Misconduct, for the various Kobe companies.
The IIC report states that the Aluminum & Copper Business was the only division where executive officers were involved in the Misconduct. Of former executive officers, two directors/executive officers were found to have been directly involved in the Misconduct before taking office as an executive officer. Even after becoming executive officers, they neither reported the Misconduct to the Board of Directors nor took any actions to have the Misconduct halted or corrected."
2
On March 5, 2018, a civil complaint was filed by Alejandro Nava, a resident of Oakland, California and Shantnu Malhotra, a resident of Sunnyvale, California (Plaintiffs) against certain named parties, including Kobe Steel, Ltd., Kobe Steel USA Inc., Kobe Steel International (USA) Inc., and Kobe Aluminum Automotive Products, LLC, all of which are subsidiaries of Kobe Steel, in the United States District Court, Northern District of California. The lawsuit relates to certain metal products manufactured by Kobe Steel allegedly used in certain vehicle models of a specific automotive manufacturer, which is one of the co-defendants in the lawsuit.
3
Who Is Affected?
Kobe provides materiel to numerous industries including: aviation, automobile, railways, nuclear power, construction, electronics and other equipment, and semiconductors. Their top customers (based on Kobe Steel revenue) are Shinsho Corp, Mitsubishi Corp, Toyota Motor, General Motors, Ford Motor, Nissan Motor and Honda Motor.
4 Kobe also supplies Boeing and Airbus with goods. Hitachi Ltd. said trains it has exported to the UK contained compromised material, as well as bullet trains in Japan.
Kobe Steel is Asia's number one manufacturer of semiconductor leadframes, the base material for chips. They make wire rod for engine valve springs found in half the world's cars, aluminum discs for half of the world's hard drives and 40% of the engine crankshafts used in large ships. In addition, Kobe Steel is one of the world's top makers of the large forged casks used to store spent nuclear fuel.
5 The company manufactures steel sheets that are used in electrical appliances, audio and office equipment, and communication equipment. Bearing steel, used in cars, machinery, precision devices and other applications, is also made by Kobe. One of their subsidiaries, Kobe Special Tube Co., Ltd., makes stainless steel tubes that are used in the aerospace industry and for nuclear power generation. The Sputtering Target Division has been developing original articles for a wide range of industrial applications including flat panel displays, optical discs, and solar cells.
6 Kobelco Research Institute, Inc. (KRI) carries out material and structural analysis, trials, physical analysis and other services. KRI also manufactures and sells target materials and test equipment for fields such as semiconductors, FPD and solar power, develops special materials, and otherwise maximizes in-company synergy to support manufacturing.
7
Kobe has shipped product with falsified specification data to 688 customers in multiple industries. Some of these customers and their products are listed below:
Affected Companies and their Products
Automakers |
Toyota Motor Corp
|
hoods and exterior parts
|
Nissan Motor Co
|
hoods and exterior parts
|
Honda Motor Co
|
hoods and exterior parts
|
Mazda Motor Corp
|
hoods and exterior parts
|
Subaru Corp
|
|
Mitsubishi Motors Corp |
|
Daihatsu Motor Co Ltd.
|
|
General Motors
|
|
Ford Motor | hoods for Ford Mondeo Sedan |
Hyundai Motor Co
|
|
Kia Motor Co
|
|
Rolls-Royce Holdings PLC
|
|
Suzuki Motor Corp
|
motorcycles |
Aerospace |
Honda
|
products used in HondaJet |
Boeing Co
|
|
Mitsubishi Heavy Industries Ltd
|
|
IHI Corp
|
|
Airbus
|
|
Kawasaki Heavy Industries Inc.
|
aircraft parts and engine components; other defense equipment
|
Shimadzu Corp
|
gearboxes for aircraft and vacuum pumps
|
Defense Equipment Suppliers |
MHI defense equipment
|
|
IHI defense equipment
|
|
Railways |
Hitachi Ltd.
|
trains exported to the UK and bullet trains in Japan
|
Central Japan Railway Company Co
|
|
East Japan Railway Co
|
|
West Japan Railway Co
|
|
Tokyo Metro Co Ltd
|
|
Hankyu Hanshin Holdings Inc.
|
|
Utilities |
Fukushima Daiichi Nuclear Plant
|
|
Chugoku Electric Power Co Inc.
|
|
Hokuriku Electric Power Co
|
|
Japan Nuclear Fuel Ltd.
|
|
Kansai Electric Power Co Inc
|
|
Kyushu Electric Power Co Inc
|
|
Tokyo Electric Power Company Holdings Inc.
|
|
Other |
Mitsui Engineering & Shipbuilding Co Ltd.
|
ship engines
|
Mitsubishi Electric Corp
|
air conditioners
|
Toshiba Corp
|
cooling equipment
|
Panasonic Corp
|
Blu-ray discs
|
Denso Corp (Toyota affiliated)
|
heat exchangers
|
Kobe has contacted the affected companies as they are found and has completed safety verifications of the products in most of those cases, although this process is continuing. As of the date of the report, 649 of the 688 companies have completed safety verifications and no safety issues have been reported up to this point.
The below information was obtained from Kobe Steel Group press releases dated October 8, 11, 13, 17 and 20, 2017 and provides details as to the Misconduct known at that time:
Copper alloy tubes |
Shinko Metal Products Co., Ltd. |
42 |
700 tons |
9/2016 - 8/2017 |
A portion of the contracted inspections (dimensions, etc.) were not done. Rewriting of inspection data prescribed in the customer's specification sheet |
Copper molds |
Shinko Metal Products Co., Ltd. |
137 |
5300 pieces |
9/2016 - 8/2017 |
Copper sheets |
Kobe Steel Ltd Aluminum and Copper Business |
40 |
|
|
|
Copper tubes (capillary tubes) |
Kobelco & Materials Copper Tube Malaysia Dsn. Bhd |
28 |
750 tons |
9/2016 - 8/2017 |
A portion of the contracted inspections (dimensions, etc.) and tests (mechanical properties, etc.) were not conducted. |
Copper tubes |
Kobelco & Materials Copper Tube (Thailand) Co., Ltd. |
5 |
1140 tons |
9/2016 - 8/2017 |
Agreed upon tensile testing was not conducted and instead hardness test was substituted. Instead, tensile testing was shortened and an estimated calculation was entered as tensile strength based on the results of the hardness tests. |
Aluminum alloy wires and aluminum alloy bars |
Shinko Aluminum Wire Co., Ltd. |
2 |
12.5 tons |
9/2016 - 8/2017 |
A portion of the contracted inspection items was not conducted and inspection data was rewritten. Unmeasured microalloyed chemical values were entered and a portion of the tensile properties, which were target values for reference, were used. |
Copper strips |
Suzhou Kobe Copper Technology Co., Ltd. |
2 |
31 tons |
9/2016 - 8/2017 |
Rewriting of inspection data of agreed upon prescribed specifications (dimensions, etc.). |
Steel wires |
Jiangyin Sugita Fasten Spring Wire Co.,Ltd. |
1 |
3525 tons |
6/2011 - 7/2017 |
A portion of the contracted inspection was not conducted |
Steel wires |
Kobelco Spring Wire (Foshan) Co., Ltd. |
1 |
306 tons |
12/2015 - 4/2017 |
A portion of the contracted inspection was not conducted |
Special steel |
Nippon Koshuha Steel Co., Ltd. |
19 |
3990 tons |
6/2008 - 5/2015 |
Rewriting the results of tests, which Kobe agreed with the customer, prescribed in the specification sheet |
Stainless steel wire |
Shinko Wire Stainless Company, Ltd. |
1 |
553 tons |
4/2007 - 5/2016 |
Rewriting the results of tests, which Kobe agreed with the customer, prescribed in the specification sheet |
Heavy plate processed products (excluding the fields of steel frames, bridges and vehicles) |
Shinko Kohan Kako, Ltd. |
1 |
3793 tons |
11/2015 - 9/2017 |
Only a portion of the measurements for plate thickness requested by the customer was not conducted. Plate thickness measurement data was rewritten to match the customer. |
Steel powder for powder metallurgy (sintering) |
Takasago Works, Kobe Steel |
one type to one customer |
140 tons/year |
Fiscal year 2016 |
Improper rewriting of inspection data of a product outside the compact density agreed with the customer |
Sputtering Target Materials |
Takasago Works |
70 |
6611 pieces |
11/2011 onward |
Not conducting tests agreed with customers and the improper writing of inspection data with regard to products outside the component values agreed with customers. |
Sputtering Target Materials |
Sputtering Target Business |
Sputtering Target Materials |
Kobelco Research Institute, Inc. |
Kobe released a statement regarding resolutions passed by the Board of Directors at a board meeting held on March 5, 2018. Among the resolutions were the acceptances of the resignations of Kiroya Kawasaki, Chairman, President, CEO and Representative Director, and Akira Kaneko, Executive Vice President and Representative Director, effective April 1, 2018. These individuals will continue to serve as directors without representational authority until they step down at the Annual General Meeting of Shareholders scheduled for late June 2018.
In addition, the Board dismissed Managing Executive Officers Takumi Fujii and Nobuaki Isono effective March 6, 2018. Executive Officer Seii Hirata was assessed an 80% reduction in remuneration for a 4-month period by the Board. In addition, a resolution was passed stating all directors, excluding those serving as independent outside directors and directors serving as members of the Audit & Supervisory Committee, and all executive officers, excluding those mentioned above, will have 10 to 50 percent of their basic remuneration reduced for a period ranging from one month to four months. In another resolution adopted at that meeting, the Board of Directors shall call for two former executives — one who previously served as a director and another who previously served as an executive officer — to voluntarily return a portion of remuneration that they received during their appointment as company executives. The Board of Directors also dismissed Yutaka Masuno, Kobelco & Materials Copper Tube Co., Ltd. President, CEO and Representative Director, and Hiroyuki Ando, Shinko Metal Products Co., Ltd. President and Representative Director, effective April 1, 2018.
8
On June 5, 2018, prosecutors and police raided Kobe Steel's main Tokyo office, company headquarters in Kobe, and three manufacturing plants. According to an article published in The Japan Times, "authorities believe the company violated a law that prevents unfair competition by systematically misrepresenting its products."
9
Individuals found guilty in the data fabrication could face prison terms of up to five years or fines up to ¥5 million ($45,422.38), or both. Kobe could face a fine of up to ¥300 million ($272,534.30).
Call to Action
Several U.S. Government agencies have been monitoring this issue. On October 16, 2017, Kobe Steel USA Inc. received a request for production of documents from the U.S. Department of Justice to produce any and all documents related to nonconformities with the specifications of products. The Defense Logistics Agency submitted an Agency Action Notice on November 15, 2017 regarding nonconforming material supplied by Kobe Steel Group and its subsidiaries. Kobe's breach involving the misuse of the JIR mark initiated the investigation.
The DLA is seeking to garner information regarding the actual nonconformities of the material, where it was sold, and to whom it was sold. According to the Agency Action Notice, there are three ways for Kobe's material to infiltrate the government's equipment and systems:
- Direct material procurements from Kobe or subsidiaries
- Procurements via a material distributor selling Kobe materials
- Procurement of equipment/systems from a vendor (either a customer of Kobe, or who purchases Kobe material from a distributor) who then uses that material to manufacture items for the Government.10
The Government asks that any government contractor who has used Kobe materials in their parts, equipment, items, systems, etc. notify their Contracting Officer/Program Office and let them know.
ERAI urges all suppliers/vendors to check your records and/or inventory to determine if you received any of the affected products and, if so, to contact your customers regarding the possibility that the items were shipped with falsified data. You are also encouraged to inform ERAI in the event you did receive some of these products.
1 Our Standards: The Thomson Reuters Trust Principles. Japan carmakers vouch for safety of Kobe Steel's aluminum parts Published 11:35 PM, October 18, 2017 Updated 8:15 AM, October 19, 2017
2 http://www.kobelco.co.jp/english/releases/1199082_15581.html; Report on the Kobe Steel Group's misconduct; March 6, 2018
3 http://www.kobelco.co.jp/english/releases/1199090_15581.html: Civil Complaint Filed Against Kobe Steel, Ltd. and A Few Other Group Companies, March 14, 2018
4 From:
https://www.trtworld.com/business/kobe-steel-fake-data-scandal-deepens-11317; Kobe Steel fake data scandal deepens; 13 Oct 2017
5 https://www.reuters.com/article/us-kobe-steel-scandal-customers-factbox/factbox-kobe-steels-affected-customers-from-computer-chips-to-space-ships-idUSKBN1D5019, November 4, 2017; Reporting by Sam Nussey, Yuka Obayashi, Osamu Tsukimori, Joe White, and Hyunjoo Jin; Editing by Raju Gopalakrishnan
6 http://www.kobelcokaken.co.jp/target/english/index.html
7 http://www.kobelco.co.jp/english/other_business/index.html
8 http://www.kobelco.co.jp/english/releases/1199083_15581.html: Changes in Representative Directors and important executives in the Kobe Steel Group, March 6, 2018
9 https://www.japantimes.co.jp/news/2018/06/05/national/prosecutors-raid-kobe-steel-quality-data-fabrication-2/#.WyP7wyApCM8
10 Agency Action Notice – Document Number AAN-U-18-097, November 15, 2017