Kasai UK aims ever higher through cobots, sustainable practices, and a culture of trust 

Providing an efficient one-stop-shop solution for customer needs, Kasai UK, a subsidiary of Kasai Group, is a full-service Tier 1 automotive interior and exterior trim manufacturer with a global presence, providing door trim and injection molded body side trim parts. “Set up in the UK in 1991 as a joint venture between Kasai and Reydel under the name of R-TEK, we originally supplied Honda and Nissan before expanding to supply Jaguar Land Rover (JLR). In 2012, we became wholly owned by Japan-based company Kasai Kogyo Co Ltd. Four years later, we were renamed Kasai UK to align with our group’s corporate identity,” begins Yuki Miyauchi, Managing Director at Kasai UK and Kasai Germany. 

Jill Usher, Deputy Managing Director at Kasai UK, delves into the diverse expertise  and services provided by the company.  “As an interior system supplier, we are involved in a series of processes such as planning, development, design, experiment, quality assurance, and production. In the UK, we currently manufacture a range of interior door trim, body side trim and hard luggage trim for Nissan Motor Manufacturing UK and JLR.  We have 25 injection and back injection molding machines ranging from 250-to-2000 tons, as well as vacuum forming, sewing, wrapping, and assembly expertise. Additionally, we are IATF16949 and ISO 14001 accredited, and are currently undergoing audits to obtain ISO 5001 accreditation in the first quarter of 2025.” 

To ensure consistency and quality across its processes, Kasai UK has implemented various cutting-edge technologies. Kevin Wilson, Deputy Managing Director, sheds light on the technologies and robots the company has invested in. “We have an Information Management System (IMS) in place that collects data from various areas within the business. This data is then analyzed by our Business Innovation, Continuous Improvement,  and Management teams in order to identify areas for improvement. Subsequently, enhancement activities are generated, and by utilizing methodologies such as Define, Measure, Analyze, Improve, and Control (DMAIC) and Plan, Do, Study, Act (PDSA), we are able to actively optimize our business operations.   

“Furthermore, we have used robot technology within our plant for many years, albeit this has predominantly entailed high investment and has been restricted by the nature of our operations. On the other hand, collaborative robots (cobots) are a relatively lower investment, have simpler programming and setup procedures, and do not require shielded work cells. Through the introduction of cobots that will handle the monotonous and dirty tasks, we aim to mitigate potential health and safety issues, thus improving the wellbeing of our operators,” he explains. 

Always striving to stay ahead of the curve, Kasai UK is rapidly advancing on its sustainability journey. Jill tells us more about the company’s approaches and efforts towards becoming greener. “As a business,  we are continually working towards our long-term sustainability goals. Installing solar panels in 2023 presented us with the opportunity to reduce our energy consumption from the grid by around 15 percent per year, resulting in an accelerated return on investment with the added benefit of reducing CO2 in excess of 240 tons annually. We have also implemented on site-electric vehicle (EV) charging stations for our fleet of company electric and plug-in hybrid vehicles.  

“In another significant sustainability initiative, we have partnered with both Durham and more closely with Northumbria University placement students to identify possible opportunities for reusing and recycling scrap materials generated as part of our manufacturing processes. As of now, this waste is still incinerated, but we aim to be able to convert it into car accessories soon, thereby generating additional revenue whilst reducing our carbon footprint. In line with our group’s sustainability policy, we actively contribute towards and engage with local communities, ensure our staff receive regular training on compliance and ethics, and are proud members of the Slave Free Alliance. Alongside our ISO 14001 environmental accreditation, we are working towards getting an ISO 5001 energy management certification as our next step. By 2030, we are dedicated to reducing our CO2 emissions by 30 percent and eliminating solvents from our processes entirely,” she states.  

Trusting relationship  

Nonetheless, environmental sustainability is but one aspect that Kasai UK prioritizes to ensure its longevity. Indeed, as Jill and Kevin point out, fostering a positive company culture to satisfy and retain customers and employees alike is paramount to success. “When it comes to our clients, we place a strong emphasis on top-notch customer service and maintaining our world class  just-in-time delivery and quality performance. Moreover, collaboration with our clients  is key to driving shared improvements  and remaining competitive. A prime example of the success of this approach is our longstanding relationship with Nissan. In the UK, we have worked with Nissan for over 35 years (and significantly longer within the group globally) and have developed a genuinely open and trusting relationship. 

Continuous training  

“We extend a similar approach to our workforce, with our company philosophy centered on creating trust, prosperity, and happiness. We strive to embed this culture through open communication and policies that encourage respect, trust, and inclusivity. Workplace health, safety, and wellbeing are very important to us, and as such, we have been involved in the Better Health at Work Award since 2014, earning the Maintaining Excellence Award for the past two years. To enhance the skills of our workforce and support progression in the workplace, we provide continuous training opportunities. Currently, we have a group undergoing Six Sigma training, and in 2024, a number of employees received First Class Honor’s degree qualifications, enabling them to progress within the business. Additionally, several employees are engaged in apprenticeship programs, while others are enrolled in short courses covering various subjects such as leadership, mental health, Microsoft Excel, and cybersecurity,” they conclude. 

Driven by its commitment to continuous improvement, Kasai UK is poised to continue delivering unparalleled value to its global clientele.  

www.kasai-na.com
www.kasai-uk.com