Eco-Friendly Development and Design
The Toyota Boshoku group takes the environment into account at each stage from development and design and procurement to production, use and disposal. We work to design products that are eco-friendly throughout their entire life cycle.
Initiatives in development and design
The design and development of environmentally friendly products at the Toyota Boshoku group is driven by parts evaluation DR*1 and SE*2.
- *1 Design Review
This entails using specialised knowledge to methodically and systematically evaluate design from the outset, make improvements and verify the results in order to secure high quality in product design. - *2 Simultaneous Engineering
This entails concurrent development through close cooperation with relevant divisions and departments in areas such as design, production engineering, procurement and suppliers, thereby enabling the elimination of wasteful restarts.
Making automotive parts lighter to increase fuel efficiency
Four years have passed since the inauguration in November 2007 of four sessions to observe trends for seats, interior trims, filters and power trains, as well as developments at other companies, and of the Weight Saving Committee comprising special working groups aimed at reducing weight over the medium and long terms through advanced development. These efforts are focused on preserving the environment and strengthening global competitiveness. In fiscal 2010, we have adopted lightweight items across the board and achieved all voluntary targets for next-generation automobiles. We will promote activities such as market research aimed at producing the world’s lightest automotive parts in fiscal 2011.
Compliance with European REACH Regulation*3
REACH Subcommittee
The REACH regulation for chemical substances went into effect in Europe in June 2008 amid a strengthening of environmental laws in recent years. The purpose of the regulation is to enable the registration and management of chemical substances in Europe as well as prohibit the production, sale and use of Substances of Very High Concern (SVHC)*4 to ensure product safety.
The Toyota Boshoku group inaugurated the REACH Subcommittee under the Product Environment Committee in December 2007 to cooperate with relevant divisions and departments and ensure thoroughgoing compliance with the REACH regulation in Europe. In fiscal 2008, we completed the inspection and registration of items for preliminary registration. In fiscal 2009, we selected and developed alternative materials to SVHCs and in fiscal 2010 completed replacement of HBCD*5, one type of SVHC, well ahead of the deadline of August 2015. We will work to develop environmentally friendly products in fiscal 2011.
- *3 A regulation on Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) enforced in Europe in June 2007
- *4 Chemical substances for which there is a concern that they may have an impact on the human body
- *5 Hexabromocyclododecane (used as a flame retardant)
Activities to reduce VOC*6 in the vehicle cabin
We have been implementing activities to reduce VOC on a project unit basis related to “Voluntary Approach to Vehicle Cabin VOC Reduction” released by the Japan Automobile Manufacturers Association, Inc. in February 2005. In addition, the VOC Subcommittee was established under the Product Environment Committee in June 2008 in response to vehicles being subject to VOC legislation in China, the first country in the world mandate legal compliance. Thereafter, related departments, including development, production engineering, plant and logistics departments, collaborated to reduce VOC levels in the cabin space. In fiscal 2008, we established an in-house system for VOC, and in fiscal 2009, we conducted activities to reduce VOC levels in each project in terms of parts and developed VOC evaluation methods. In fiscal 2010, we incorporated these methods into the development of components and into actual vehicles. We will continue to promote ways to reduce VOC levels in fiscal 2011.
Development of plant-derived materials for interior materials
A door trim base material using kenaf base material was first adopted for the Toyota Celsior, which was launched in the domestic market in 2000. Currently, kenaf is being used in numerous products for interior materials, with around 3,000 tons of kenaf fibre presently being used every year. Aiming to stabilise the cost, quality and production volume of kenaf fibre, we are developing new cultivation techniques at a test farm in Indonesia. In addition to seed development, the test farm is promoting the development of technologies for increasing yields by optimising cultivating conditions and all-year-round cultivation, as well as retting technology*6 for the efficient extraction of fibres from kenaf and mechanisation to improve cultivating effectiveness. In addition, the knowledge and technology gained from the test farm are utilised by Toyota Boshoku to grow kenaf in Indonesia along with the consignment of cultivation to agricultural producers.
- *6 Technology to extract fibre from the cortical layer of kenaf bast by refining the material via water-based microorganisms
