2013年4月15日 星期一

日本航太製造業力圖東山再起 Japan Re-emerges in the Aerospace Arena With a New Jet

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Japan Re-emerges in the Aerospace Arena With a New Jet

TOKYO — As a small boy, Teruaki Kawai watched wide-eyed as American DC-3s took off and landed at a small airport across an inlet from his home on the Hiroshima coast.
Japan’s golden era of aviation, which culminated with the feared and respected Mitsubishi Zero fighter planes, had ended a decade earlier along with World War II. Banned from making planes by American occupiers after the war, then allowed only to make parts for American military jets, Japan’s aircraft industry was a shadow of its former self.
If all goes well this year, Mr. Kawai, now 65 and president of the Mitsubishi Aircraft Corporation, will preside over Japan’s biggest aviation comeback since the war. In late 2013, the company plans the first flight of its Mitsubishi Regional Jet, a sleek, 90-seat commercial plane that is Japan’s bid to break into the industry’s big leagues after almost 70 years.
“For decades, we were confined to supplying parts for other passenger jets. But we’re finally heading into new territory,” Mr. Kawai said in a recent interview at Mitsubishi Aircraft’s Tokyo office.
Mitsubishi’s comeback was abetted in large part by Boeing’s outsourcing more of its aircraft manufacture to overseas suppliers. As Boeing came to rely on foreign contractors, Japanese manufacturers moved in, designing and supplying some of the jet’s most vital sections.
A full third of Boeing’s new 787 Dreamliner is supplied by Japanese manufacturers, including Mitsubishi Aircraft’s parent company, Mitsubishi Heavy Industries, which makes the jet’s carbon-fiber composite main wings.
Even so, Boeing and Mitsubishi could not be further apart in their approach to jet-building. In contrast to the cutting-edge 787, Mitsubishi’s regional jet uses only a little of the advanced carbon fiber that its parent company supplies to Boeing.
Neither does the regional jet use the volatile lithium-ion batteries that have become a major headache for Boeing, overheating on two planes in January and prompting American and Japanese safety regulators to ground the entire 787 fleet.
Mitsubishi’s caution underscores the importance, to the company and to Japan, of getting the regional jet project off the ground in an industry where reputation for reliability is paramount. That is especially the case, experts say, for a country long absent from the business of making planes, save military jets under license from the United States, and a series of small private jets.
In the late 1950s and 1960s, Mitsubishi participated in a consortium to develop the YS-11 plane, a 60-seat turboprop airliner led and largely financed by the Japanese government, which was eager to restart the country’s aviation industry.
Leading the YS-11’s design was Teruo Tojo, one of the Mitsubishi Zero fighter’s original engineers and the second son of Hideki Tojo, the Japanese wartime leader who was executed as a war criminal by the Allies. But with no experience in making civilian jets, Mr. Tojo and his team of engineers struggled with the YS-11’s design.
Burned by the YS-11 flop, Japan shifted its aviation strategy to supplying, and learning from, the largest aircraft makers of the time, of which the largest was Boeing. Japanese suppliers have played an increasingly bigger role in building Boeing aircraft, supplying 15 percent of the 767 jet, 21 percent of the 777, and 35 percent of the 787.
The Japanese government quickly became one of the largest financial backers of those projects, handing out billions of yen in subsidies to help Japanese suppliers develop technology and win lucrative contracts from Boeing. Though the government declines to reveal exact numbers, estimates by researchers at the State University of New York of how much Japan has handed out to 787 suppliers in subsidies and loans over the past decade are as high as $1.6 billion. .
Boeing, which is based in Chicago, outsources its parts manufacturing to pare its investment in research and development, design, manufacturing and also its work force. These Boeing contracts have kept tens of thousands of Japanese workers busy for years, and still account for about 40 percent of jobs in the industry. They also help keep Japanese companies on the forefront of crucial aeronautical technology.
And in a cozy quid pro quo, Japan’s biggest airlines have for years bought their planes almost exclusively from Boeing — an unusual practice among global carriers, which tend to play Boeing off against its rival, Airbus, to negotiate better terms and prices.
“It’s been a ‘you scratch my back, and I’ll scratch yours’ kind of relationship that made both sides captive to each other,” said Takanori Maema, an aeronautics expert and former engine designer at the IHI Corporation, another major Boeing supplier. “But all along, Japan always aspired to build its own plane.”
At the same time, the Japanese government was ready to give passenger plane manufacturing another try, as it looked in the early 2000s for ways to bolster Japanese exports and revitalize the country’s stagnant economy.
In 2003, it announced bold plans to finance the development of compact, fuel-efficient aircraft. By the mid-2000s, Mitsubishi executives were gearing up to develop a passenger jet. The company placed Mitsubishi Aircraft’s new headquarters in its prewar offices in Nagoya, where engineers designed the Zero.
The Mitsubishi Regional Jet, announced in 2008, is conservative in its use of new technologies and materials.
Still, Mitsubishi’s regional jet boasts about 20 percent in fuel savings compared to similar size Brazilian-built Embraer 190 jets. Much of the fuel economy comes from its use of new engines from the American manufacturer, Pratt & Whitney. The plane’s wings are thinner and are more aerodynamic than those on similar models, also improving energy efficiency. Mitsubishi says newly designed seats on the M.R.J. also offer wider seats than rival aircraft: 18.5 inches across compared with 17.3 inches on Canada’s Bombardier’s CRJ700 series.
The company has 165 firm orders to date for the $42 million jet, and it aims to secure as many as 5,000 orders over the next two decades — a goal some experts dismiss as unrealistic.
It faces well-established rivals like Bombardier and Embraer. The Russians and Chinese are also making inroads into plane-building. By bolstering its aviation credentials, Japan could also keep upstarts in South Korea, Taiwan and China from encroaching on its lucrative Boeing work, which analysts say contributes around a fifth of Mitsubishi’s roughly $5.7 billion aeronautics business.
“As a boy, I didn’t think that Japan would build a plane again,” Mr. Kawai said. “But it’s been over a half-century. It’s high time for Japan to give it another go.”

苦幹數十年,日本飛機製造業力圖東山再起

Yuya Shino/Reuters
三菱飛機公司即將推出一款90座商用飛機,圖為社長川井昭陽。

東京——川井昭陽(Teruaki Kawai)小時候,會目不轉睛地看着與他在廣島海岸的家一灣之隔的一座小機場,目送美國DC-3s飛機起飛、降落。
那時候,日本航空業的黃金時期,已經隨着二戰的終結,在10年前落下了帷幕。那個時代的頂峰,以令人敬畏的三菱零式(Mitsubishi Zero)戰鬥機為代表。戰後,美國佔領者起初禁止日本製造飛機,後來又只允許日本給美國軍用飛機製造零部件。日本的飛機產業,與過去相比變得十分弱小。
如果今年一切順利的話,65歲的三菱飛機公司(Mitsubishi Aircraft Corporation)社長川井昭陽,會給日本航空業帶來一次最為重大的東山再起案例,該公司計劃在2013年底進行三菱支線飛機 (Mitsubishi Regional Jet)的首次飛行。這款設計風格明快的商用飛機有90個座椅,它是日本在將近70年後,再次躋身航空業高端競賽的一次嘗試。
川井昭陽最近在三菱飛機公司東京辦公室接受採訪時稱,“幾十年來,我們一直局限於為其他客機生產零部件,現在我們終於要進入新的領域了。”
三菱的回歸,主要得益於波音公司(Boeing)將大部分飛機製造外包給國外供應商。隨着波音逐步依賴外包業務,日本製造企業開始逐步走向核心,設計並製造波音飛機的一些最關鍵部件。
波音公司新型的787“夢想客機”(Dreamliner)中,有整整三分之一是由日本製造商提供的,其中包括三菱飛機的母公司三菱重工(Mitsubishi Heavy Industries),該公司為飛機製造了碳纖維複合材料主翼。
儘管如此,波音和三菱在飛機製造上採取的策略卻差異巨大。與先進的787飛機不同,三菱的支線飛機僅使用了一小部分其母公司向波音供應的先進碳纖維材料。
三菱支線飛機也沒有使用不穩定的鋰離子電池。這種電池讓波音大為頭疼,今年1月曾在兩架客機上出現過熱,促使美國和日本的安全監管部門下令停飛了所有的787飛機。
三菱的謹慎顯示出,對於該公司和日本來說,在一個可靠的聲譽至關重要的行業,讓這款支線飛機成功起飛有多麼重要。專家表示,對於一個退出飛機製造行業已久,只製造過小型私人飛機,和在美國的授權下製造過軍用飛機的國家來說尤其如此。
20世紀50年代末和60年代,三菱公司曾參與過一個研發60座渦輪螺旋槳客機YS-11的團隊,該項目由日本政府牽頭,日本政府也提供了大部分資金,當時日本政府正急於重振該國的航空工業。
領導YS-11飛機設計的是三菱零式戰鬥機最初的工程師之一東條輝雄(Teruo Tojo), 他也是日本戰時的首相東條英機(Hideki Tojo)的次子。東條英機後來作為戰犯被盟軍執行死刑。但是由於東條輝雄沒有任何設計民用飛機的經驗,他和他的工程師團隊在YS-11的設計上舉步維 艱。
受到YS-11挫敗的影響,日本轉變了本國航空工業的戰略,轉而向當時最大的飛機製造商供應零部件並向其學習,當時最大的飛機製造商是波音公司。日 本供應商在波音飛機的製造中扮演了越來越重要的角色,767飛機的15%,777的21%,787的35%都是由日本供應商提供的。
日本政府迅速成為了這些項目最大的資金支持者之一,投入了數百億日元的補貼幫助日本供應商發展技術,也幫助企業從波音公司贏得回報豐厚的合同。儘管 日本政府拒絕透露具體數字,但紐約州立大學(State University of New York)的研究人員估計,日本在過去10年里向787飛機的供應商提供的補貼和貸款,多達16億美元(約合99億元人民幣)。
總部位於芝加哥的波音公司將零部件生產外包出去,從而逐漸減少其在研發、設計、製造上的投資,並逐步減少勞動力規模。波音公司的這些合同,多年來為 數以萬計的日本人提供了就業崗位,這些崗位至今仍占整個航空工業的約40%。這些合同還使日本公司走在了關鍵航空技術的最前沿。
作為一個優厚的交換條件,多年來日本最大的航空公司幾乎都只從波音購買飛機。這種做法在全世界的航空公司中並不常見,它們會有意挑起波音與其對手空中客車公司(Airbus)的競爭,從而在談判中取得更有利條款和更低的價格。
曾在波音公司的另一家大型供應商IHI公司任工程設計師的航空學專家前間孝則(Takanori Maema)稱,“這是一種‘互惠互利’的關係,讓雙方都離不開對方。但是一直以來,日本都渴望能製造自己的飛機。”
與此同時,在本世紀初,隨着日本政府開始想方設法刺激出口、重振本國停滯的經濟,日本政府也準備好了再度嘗試製造客機。
2003年,日本政府宣布一個大膽的計劃,為研發小型節能的飛機提供資金支持。到2005年前後,三菱公司的高管已經做好要研發一架客機的準備。該公司將三菱飛機公司的新總部設在其位於名古屋的戰前辦公地點,就是在那裡,工程師設計出了零式戰鬥機。
於2008年宣布的三菱支線飛機在使用新技術和材料方面都很保守。
但是,三菱支線飛機號稱和巴西航空工業公司(Embraer)製造的E190飛機相比,可以節約20%的油耗。這兩個機型大小相似。該飛機之所以節 省油耗,主要是因為採用了美國製造商普拉特·惠特尼公司(Pratt & Whitney)的新發動機。和同類型號的飛機相比,這款飛機的機翼更加輕薄,也更加符合空氣動力學,而且還在改善能耗上有所表現。三菱公司稱,三菱支線 飛機上最新設計的座椅還比競爭對手的寬:座寬18.5英寸(46.99厘米),而加拿大龐巴迪公司(Bombardier)的CRJ700系列的座椅寬度 只有17.3英寸(43.9厘米)。
目前,三菱公司已經獲得了165個確定訂單,訂購這種價值4200萬美元的飛機,該公司的目標是在接下來的20年中拿到5000份訂單,一些專家認為這一目標不切實際。
三菱面對着像龐巴迪和巴西航空工業公司這樣一些久負盛譽的競爭者對手。俄羅斯和中國也正在打入飛機製造業。通過提高本國航空業的水平,日本還可以確 保韓國、台灣和中國大陸新崛起的公司不會侵蝕自己從波音公司得來的寶貴項目,分析人士稱,這一部分業務在三菱公司價值約57億美元航空業務中約佔五分之 一。
川井昭陽稱,“我小的時候覺得日本不會再製造飛機了。但是半個多世紀已經過去了。現在正是日本要再次嘗試的好時機。”
翻譯:張亮亮

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