CSR Social Activities

Report on Environmental Activities

Fiscal 2016 Results (2050 Environmental Vision)

[Boundary of reporting]

  • Toyota Boshoku: Global Mainstay Hub, plants and offices in Japan (18 plants)
  • Japan affiliates: Production entities (9 companies), others (7 companies)
  • The Americas region: Regional Management & Collaboration Hub (1 company), production sites (10 companies)
  • Asia & Oceania region: Regional Management & Collaboration Hub (1 company), production sites (12 companies)
  • China region: Regional Management & Collaboration Hub (1 company), production sites (12 companies)
  • Europe & Africa region: Regional Management & Collaboration Hub (1 company), production sites (8 companies)

Establishment of Low Carbon Society (Climate Change, CO2)

From the 2020 Environmental Action Plan, the Toyota Boshoku group used production volume instead of sales, which is susceptible to external factors, for the denominator of intensity performance metrics used to manage the action items 1-7 so that improvements are more accurately measured. Likewise, the calculation method for CO2 emissions from logistics (item 8) will be revised in order to measure the improvement more accurately.

(Assessment : Achieved)
Action item Specific action FY2016 targets FY2016 results Evaluation
Production 1 Promote the development of innovative production technology with low CO2 emissions
  • Reduce CO2 emissions from new processes by 30%, promote the development of innovative production technology
  • Incorporate energy conservation measures for new equipment (reduce 30% from standard equipment)
  • Completed incorporation of energy conservation measures as planned
  • Downsize processes, reduce transfer distance, and minimise BOM
  • Draft and implement development items
  • Completed development of new method and installation of equipment that downsized processes as planned
  • Reduce the amount of energy used through the development of next generation moulding, decoration & assembly methods
  • Promote the reduction of CO2 emissions through the introduction of co-generation equipment
  • Systematically conduct installation of co-generation equipment
  • Completed installation and started operation (December) of gas engine cogeneration equipment with a capacity of 2,400kW at the Sanage Plant
2 Promote the use of renewable energy suitable for respective countries and regions
  • Expand the areas to introduce renewable energies, considering the characteristics of inrespective countries and regions (Economic efficiency/Reduction of CO2 emissions)
  • Conduct examination of characteristics of respective countries and regions, target values and a plan for introducing renewable energies
  • Completed examination of characteristics of respective countries and regions and draft of a plan to introduce renewable energies
3 Study the possibility of utilising next generation energy within the company, and define the mid- to long-term outlook for the utilisation of such energy
  • Study the possibility of utilising next generation energy for processes and motors, and clarify the outlook for the utilisation of such energy
  • Research trends in hydrogen energy use and study the possibility of using fuel cells
  • Completed draft of a plan to install a model line for fuel cell use
4 Minimise the CO2 emissions in daily production activities
  • Thoroughly eliminate waste in energy use through the pursuit of improved productivity and E-JIT activities*1
  • Eliminate waste through energy conservation diagnostics and determine and implement investment zero items decisively
  • Determined investment zero items decisively and implemented improvement measures through energy conservation diagnostics and patrols
  • Reduce CO2 by completing investment zero items*2 decisively, and promote and maintain the activity
  • Actively replace low-efficiency equipment with high-efficiency equipment
  • Upgrade to high-efficiency equipment in a planned manner and study equipment on premises so as to draft a medium- to long-term upgrade plan
  • Implemented planned upgrade and completed research into equipment globally
  • Promote the understanding and reduction of the energy basic unit for products & processes
  • Promote the understanding of energy basic unit and install weighing machines to make improvements
  • Completed installation of weighing machines such as seat assembly processing as planned
Product 5 Product development that contributes to top-level fuel efficiency
  • Reduced product weight (Seat, interior & exterior, filter/powertrain)
  • Heat management (Reduced air-conditioning load through the development of heat insulation materials)
<Seat>
  • Develop lightweight frame for rear seat
<Interior & Exterior>
  • Decide on use of moulded foam door trims with high impact resistance

  • Assess specifications for TPO*3 surface materials/ needle-punch*4 non-woven surface material that secure 40% in infrared reflectance
<Seat>
  • Completed evaluation of prototype
<Interior & Exterior>
  • Completed verification of mass production for moulded foam door trims with high impact resistance
  • Completed assessment of marginal performance of high modifier

  • TPO surface material: Completed development as surface material with infrared reflectance capability
  • Needle-punch non-woven surface material: Confirmed addition of infrared reflectance capability
6 Promote product development to support next generation automobiles
  • Increase the mass production of HV motor components and FC components
<HV motor>
  • Secure orders for prototype
<FC (fuel cell)>
  • Secure orders for mass production of FC parts
<HV motor>
  • Received orders for prototype
<FC (fuel cell)>
  • Received orders for FC parts
7 Develop and commercialise products using plant-derived materials
  • Utilisation of plant-derived materials for automotive parts
  • Formulate strategy for expanding sales of kenaf
  • Newly apply kenaf to latest models
  • Completed plan for expanding application of kenaf
  • New application decided for Corolla
Logistics 8 Reduce CO2 emissions through the pursuit of efficient logistics activities
  • Reduce the CO2 emissions through improved transportation efficiency and further improvement of activities with low fuel efficiency
Target value: 8,441t or less Result: 6,593t
[Targets regarding 1~8]
Region Base year Unit 2020 targets FY2016 targets FY2016 results Evaluation
Production Toyota Boshoku group FY2010 Basic unit: t-CO2 / 1,000 unit Reduce 15% 36.0 35.5
  Toyota Boshoku
(non-consolidated)
FY2008 Basic unit: t-CO2 / 1,000 unit Reduce 17% 19.1 18.1
FY2008 Emission: t-CO2 Reduce 17% 62,280 57,143
Logistics Toyota Boshoku
(non-consolidated)
FY2010 Emission: t-CO2 Reduce 10% 8,018 6,593
  • *1 Energy-Just In Time activities: This refers to using just the required amount of energy at the required time to produce the required amount. Activities to eliminate waste when using energy
  • *2 Item enabling efficient energy conservation simply through modification without the need for investment
  • *3 Thermo Plastic Olefin: Olefinic thermoplastic elastomer
  • *4 A manufacturing process for non-woven textiles

Establishment of Recycling-based Society

From the 2020 Environmental Action Plan, the Toyota Boshoku group used production volume instead of sales, which is susceptible to external factors, for the denominator of intensity performance metrics used to manage the action items 11 so that improvements are more accurately measured.

Action item Specific action FY2016 targets FY2016 results Evaluation
Production 9 Reduce the amount of water used in production activities and wastewater
  • Reduce the amount of water used in production activities and wastewater (Development of processes with minimum consumption)
  • Draft and implement respective development items
  • Completed planned development items as planned
  • Continue promoting water usage reduction activities in consideration of the water situation in respective countries and regions
    ・Reduce the water consumption by eliminating waste and increasing efficiency
    ・Reduce the amount of water used by recycling
  • Promote programmes to reduce water consumption through daily kaizen activities in consideration of the water situation in respective countries and regions
  • Reuse wastewater from processes and rainwater depending on application
  • Switch to processes with highly efficient water use and use with high efficiency
  • Enhance daily management with flow meters for each channel
  • The Americas: Collected rainwater and used it as water for toilets, etc.
  • Asia & Oceania: Reduced water consumption by integrating plate cleaning machines
  • China: Reused treated wastewater from processes for watering green spaces
Logistics 10 Reduce the use of fossil fuel resources through the utilisation of plant-derived materials
  • Promote the use of recycled materials & drive further recycling
  • Promote the development & design enabling effective use of resources through the further utilisation of plant-derived materials
  • Enable 100% recycling of kenaf base material
  • Make scenarios for use of plant-derived material (world technology, trends, Toyota Boshoku policy)
  • Recycled kenaf base material into woodchips for Misawa Home (commercialisation complete)
  • Confirmed establishment of technology for plant-derived material for 2025
Production 11 Reduce the amount of waste generated in production activities and promote the effective use of resources
  • Development of production technology to generate less waste
  • Draft and implement respective development items
  • Completed planned development items as planned
  • Promote the minimisation of waste through daily kaizen activities
  • Promote the production of RSPP*5 effectively utilising resources (waste)
  • Reduce waste through daily kaizen activities
    - Promote waste reduction activities through countermeasures at source of origin such as improving yield
    - Implement activities to reduce resource loss (separation, recycling)
  • Promote RSPP production through effective utilisation of resources (waste)
  • Japan: Used waste as material in the trial stage prior to mass production and reduced the volume of water loss from coating sludge
  • The Americas: Improved pallet recovery by shifting from free to paid collection
  • China: Shifted from drum cans to plastic tanks for packaging containers for polyurethane material and made them returnable
Logistics 12 Reduce the amount of packaging materials used in logistics activities and effective use of resources
  • Promote the use of returnable containers and lighter-weight packaging materials. Further promote the reduction of packaging materials used
  1. 1: Consumption of packaging material
    2,190t/year or less
  2. 2: No. of packaging improvements: At least 6 per year
  1. 1: Consumption of packaging material
    2,115t/year (Amount reduced: 74t/year)
  2. 2: No. of packaging improvements: 6 per year (Amount reduced: 7.6t/year)
[Targets regarding 11·12]
Region Base year Unit 2020 targets FY2016 targets FY2016 results Evaluation
Waste emissions Japan region FY2010 Basic unit: t / 1,000 units Reduce 10% 1.72 1.32
  Toyota Boshoku
(non-consolidated)
FY2008 Basic unit: t / 1,000 units Reduce 12% 1.9 1.26
Zero direct landfill waste*6 Maintain zero direct landfill waste
Packing and packaging material usage Toyota Boshoku
(non-consolidated)
FY2010 Usage: t Reduce 12% 2,190 2,115
  • *5 Recycled Sound-Proofing Products: Automotive acoustic material made from urethanes and fibres separated and recycled from automobile shredder residue
  • *6 Definition of zero direct landfill waste: Rate of direct landfill waste is less than 1%

Establishment of Symbiotic Society

Action item Specific action FY2016 targets FY2016 results Evaluation
General 13 Promote the environmental social contribution programmes through forest-creating activities / forest conservation activities
  • Promote strengthening of forest-creating and greening activities through social contribution activities [Tree planting number 170K trees (Cumulative No.: 500K trees)]
  • Promote forestation activities in collaboration with NPOs
  • Promote the awareness-raising activities and education for “forest & nature conservation”
  1. 1. Global forestation activities
    (1) Draft a basic plan
    (2) No. of trees to plant: 7,000
    (3) Research each region and external organisations
  2. 2. Promote reforestation activities in Japan
    (1) Implement as planned
  3. 3. Participate in and cooperate with All-Toyota Harmony with Nature Working Group
  1. 1. Plant trees globally
    (1) Completed draft of basic plan
    (2) No. of trees planted: 16,000
    (3) Researched regions and external organisations
  2. 2. Promote reforestation activities in Japan
    (1) Forest management activities: 10 times
    (2) No. of trees planted: 200
  3. 3. All-Toyota Harmony with Nature Working Group
    (1) Cooperation with events/studies: 4 times
    (2) Shared information on group activities

Environmental Management

Action item Specific action FY2016 targets FY2016 results Evaluation
General 14 Promote the reinforcement of the consolidated environmental management
  • Build the structure to promote 2050 Environmental Vision and develop a scenario/road map to achieve the targets
  • Announce and deploy internally the 2050 Environmental Vision and 2020 Environmental Action Plan
  • Announced and deployed internally the 2050 Environmental Vision and 2020 Environmental Action Plan, and reflected these in regional policy
  • Toward 2050, promote the development of products, materials and methods and clarify the outlook for such development
  • Formulate a roadmap for reducing CO2 that runs up until 2050
  • Completed formulation of scenario to reduce CO2 in development, design, production technology and at plants
  • Strengthen the environmental burden reduction activities through the enhancement of the activities of the environmental committee
  • Implement mutual audits to prevent abnormalities and complaints
  • Conducted mutual audits between plants at Toyota Boshoku to prevent abnormalities and complaints
  • Further promote continuous improvement through the enhanced operations of the environmental management system
  • Create a model manual for introducing ISO 14001: 2015 and provide education on how to operate
  • Newly acquire ISO 14001 certification (1 company)
  • Formulated and distributed a model manual. Started operating at each plant and completed internal audits
  • Acquired ISO 14001 certification at TB Logistics Service
15 Strengthen the chemical substance management system
  • Expand and strengthen the control of chemical substances contained in products
  • Promote reduction of VOC in products (acetaldehyde)
  • Worked on developing technology to reduce VOCs after specifying contributing factors
  • Promote the replacement with substances with less environmental burden through the development of alternative technologies
  • Promote replacement of surface material containing decaBDE*7
  • Completed evaluation of substitute surface material
  • Establish a control structure for processed chemicals including raw materials and indirect materials
  • Conduct audits of the status of chemical substance management
  • Audit the creation of a system enabling purchase of raw materials and secondary materials with unexamined components [Target: Zero incidences of non-conformance]
  • Conducted audit of chemical substance management
  • Confirmed on-site the status of entry management of raw materials and secondary materials with unexamined components that cannot be purchased [Result: Zero incidences of non-conformance]
16 Reduce the VOC emissions from production activities
  • Promote continuous reduction of VOC emissions through daily improvement activities
  • Reduce the amount of waste chemical substances through the introduction of VOC treatment equipment and the development of processing methods
Promote activities to reduce VOCs through daily kaizen activities
  • Improve coating efficiency by optimising application conditions
  • Switch to products containing low amount of VOCs and water-based solvent
  • Increased coating efficiency by changing coating application gun
  • Changed to products containing low amount of VOCs
  • Switched from organic solvent to water-based solvent
  • Reduced excess painting coating by improving workers’ skills
Region Base year Unit 2020 targets FY2016 targets FY2016 results Evaluation
Toyota Boshoku
(non-consolidated)
FY2010 Emission: t Reduce 10% 577 501
17 Promote environmental activities in collaboration with business partners (suppliers)
  • Strengthen the cooperation with suppliers to promote environmental activities
  • Promote collaboration to establish a structure to work on climate change, water scarcity, resource recycling and environmental symbiosis
  • Continue confirmation of suppliers who have attained ISO 14001 or related certification (target: 29 companies)
  • Continued confirmation in line with plan (29 of 29 companies)
18 Promote the environmental management in product development
  • Establish a target management system of life cycle and promote the environmental burden reduction activities in the development & design phases
  • Calculate LCA*8 in model products
  • Completed calculation of LCA in core products
19 Strengthen environmental education to pass the environmental conservation activities on to future generations
  • Organise “Environmental seminars” in collaboration with NPO to spread the activities
  • Initiated collaboration with NPO
  • Completed examination of collaboration style with NPO
  • Continue to provide visiting education programmes (Tailored education programmes to meet the demand of local schools)
  • Provide visiting education programmes (2 schools)
  • Provided visiting education programmes (2 schools) (Themes: global warming, resources, water)
20 Enhance communication with stakeholders through active disclosure of environmental information
  • Communicate activity information to all the company members through internal newsletters/briefing sessions
  • Further enhance the provision of environmental information through Toyota Boshoku Report and other means
  • Disclose information to the environmental assessment agency proactively and enhance communication activities
  • Assess environmental information integrated system
  • Release environmental special site
  • Assessed international environmental information integrated system and partially started trial operation
  • Assessment of environmental special site was completed
  • *7 Deca Bromo Diphenyl Ether (Fire retardant)
  • *8 Life Cycle Assessment: Overall assessment for total environmental impact of products from raw materials through to production, use and up to disposal