CSR Social Activities

Report on Environmental Activities

Fiscal 2018 Results (2020 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 (11 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

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、☓:Not achieved)
Action item Specific action FY2018 targets FY2018 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
  • Aim to reduce CO2 emissions in development items over the medium to long term
  • Target figures were set for CO2 reduction until 2030 in production technology and development divisions. Currently identifying items for development that include enhancing productivity.
  • Downsize processes, reduce transfer distance, and minimise BOM
  • 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
  • Look into introducing co-generation equipment in factories in addition to the Sanage Plant and Gifu Plant and formulate a medium- to long-term plan
  • Looked into introduction at Kariya Plant and Takaoka Plant and completed incorporation into medium- to long-term plan
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)
  • Formulate medium- to long-term plan for renewable energy
  • Completed formulation of scenario to introduce renewable energy by 2030
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
  • Look into self-supporting renewable energy supply system
  • Completed as planned
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
  • Identify waste via energy conservation patrols and implement 30% of investments zero items
  • Achieved fiscal 2018 target with 30% implementation rate of investments zero items
  • Reduce CO2 by completing investment zero items*2 decisively, and promote and maintain the activity
  • Actively replace low-efficiency equipment with high-efficiency equipment
  • Formulate a medium-term upgrade plan for motors
  • Completed draft of medium-term upgrade plan for motors
  • Promote the understanding and reduction of the energy basic unit for products & processes
  • Draft medium-term plan for energy weighing system
  • Completed draft medium-term plan for energy weighing system that enables understanding at the energy basic unit
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>
  • Shift to production preparation stage for lightweight rear seat frame
<Interior & Exterior>
  • Make production preparations aimed at commercialisation
  • Expand sales of lightweight products to other car models and car parts
<Unit components>
  • Aim to enable production of lightweight cylinder head covers
<Seat>
  • Completed shift as planned
<Interior & Exterior>
  • Moulded foam door trim material using kenaf employed in Lexus LS
<Unit components>
  • Achieved target for production in as planned
6 Promote product development to support next generation automobiles
  • Increase the mass production of HV motor components and FC components
  • Expand orders and make production preparations for HV motor parts and fuel cell parts
  • Completed as planned
7 Develop and commercialise products using plant-derived materials
  • Utilisation of plant-derived materials for automotive parts
  • Newly employ kenaf-based parts
  • Moulded foam door trim material using kenaf employed in Lexus LS
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: 7,935t or less Result: 7,119t
[Targets regarding 1~8]
Region Base year Unit 2020 targets FY2018 targets FY2018 results Evaluation
Production Toyota Boshoku group FY2011 Basic unit: t-CO2 / 1,000 unit Reduce 15% 35.2 34.6
  Toyota Boshoku
(non-consolidated)
FY2009 Basic unit: t-CO2 / 1,000 unit Reduce 17% 18.7 17.4
FY2009 Emission: t-CO2 Reduce 17% 60,911 54,867
Logistics Toyota Boshoku
(non-consolidated)
FY2011 Emission: t-CO2 Reduce 10% 7,935 7,119
  • *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

CO2 emissions data that has been assured by an independent assurance provider is marked with this ▶
assurance symbol (click here for details).

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 FY2018 targets FY2018 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 development items aimed at achieving the zero emissions in production processes challenge
  • Completed draft of development items concerning reduction of water consumption
  • 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
  • Japan : Completed activities to prevent waste and water leaks through water matering system for each process and equipment
  • The Americas : Completed activities to conserve water and prevent water leaks by optimising cooling tower operation
  • Europe & Africa: Reused cleaning fluid in filter cleaning process and reused RO membrane*3 backwash water
  • Asia & Oceania : Reused cooling tower water in toilets
  • China : Shortened cleaning time by improving paint cleaning efficiency
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
  • Establish recycling technology for leftover materials from next-generation cars (kenaf-based moulded foam material)
  • Completed as planned
  • Promote the development & design enabling effective use of resources through the further utilisation of plant-derived materials
  • Formulate roadmap for development of plant-derived materials
  • Completed formulation of material development roadmap
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*4 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)
  • Continue promotion of RSPP production through effective utilisation of resources (waste)
  • Japan:Reduced resin waste volume by decreasing discard shots during color change, etc. Separating profitable material of seat assembly waste
  • The Americas:Improved carpet yield and reused pallets
  • Europe & Africa:Reused cleaning fluid from filter cleaning process
  • Asia & Oceania:Reduced material loss during color change with injection moulding machine
  • China:Reduced cleaning fluid waste by revising cleaning frequency of urethane raw material processing tank
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
    2,262t/year or less
  2. 2: No. of packaging improvements: At least 6 per year
  1. 1: Consumption of packaging material
    2,111.7t/year (Amount reduced: 74t/year)
  2. 2: No. of packaging improvements: 6 per year (Amount reduced: 5t/year)
[Targets regarding 11·12]
Region Base year Unit 2020 targets FY2018 targets FY2018 results Evaluation
Waste emissions Japan Region FY2011 Basic unit: t / 1,000 units Reduce 10% 1.7 1.5
  Toyota Boshoku
(non-consolidated)
FY2009 Basic unit: t / 1,000 units Reduce 12% 1.87 1.4
Zero direct landfill waste*5 Maintain zero direct landfill waste
Packing and packaging material usage Toyota Boshoku
(non-consolidated)
FY2009 Usage: t Reduce 12% 2,262 2,112
  • *3 Reverse Osmosis mebrane: Semipermeable membrane that only allows through extremely small water molecules with hole diameter of 0.1 nanometers
  • *4 Recycled Sound-Proofing Products: Automotive acoustic material made from urethanes and fibres separated and recycled from automobile shredder residue
  • *5 Definition of zero direct landfill waste: Rate of direct landfill waste is less than 1%

Establishment of Symbiotic Society

Action item Specific action FY2018 targets FY2018 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) Prepare action plan
    (2) No. of trees to plant: 16,000
  2. 2. Promote reforestation activities in Japan
    (1) Forest maintenance: 12 times
    (2) No. of trees to plant: 200
  3. 3.All-Toyota Harmony with Nature Working Group
    (1) Cooperate with and participate in event: 4 times
    (2) Disseminate information on group activities throughout the organisation
  1. 1. Global forestation activities
    (1) Completed implementation plan
    (2) No. of trees planted: 30,327
  2. 2. Promote reforestation activities in Japan
    (1) Forest maintenance implemented 10 times
    (2) No. of trees planted: 323
  3. 3. All-Toyota Harmony with Nature Working Group
    (1) Cooperated with and participated in event 6 times
    (2) Disseminated information on group activities throughout the organisation

Environmental Management

Action item Specific action FY2018 targets FY2018 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
  • Toward 2050, promote the development of products, materials and methods and clarify the outlook for such development
  • Formulate medium- to long-term plan for achievement of 2050 Environmental Vision (concrete action plan, reduction targets, etc.)
  • Completed formulation of scenario and roadmap to 2030
  • Strengthen the environmental burden reduction activities through the enhancement of the activities of the environmental committee
  • Conduct mutual audits to prevent abnormalities and complaints and implement best practices across the organisation
  • Zero abnormalities and complaints
    Completed as planned
  • Further promote continuous improvement through the enhanced operations of the environmental management system
  • Conduct scheduled update of ISO 14001 certification (FY2016 edition)
  • Completed shift in Japan region at all plants in fiscal 2018
    Planned to complete shift overseas by September 2018
15 Strengthen the chemical substance management system
  • Expand and strengthen the control of chemical substances contained in products
  • Eliminate use of solvents for adhesives
    (start development and aim for good performance)
  • Complete replacement of surface material containing decaBDE*6
  • Completed as planned
  • Completed compliance with decaBDE regulation
  • Promote the replacement with substances with less environmental burden through the development of alternative technologies
  • Establish a control structure for processed chemicals including raw materials and indirect materials
16 Reduce the VOC*7 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 film thickness by improving workers' skills
Region Base year Unit 2020 targets FY2018 targets FY2018 results Evaluation
Toyota Boshoku
(non-consolidated)
FY2011 Emission: t Reduce 10% 562 521
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
  • Hold briefing for revised Green Purchasing Guidelines
  • Conducted supplier self-assessments
  • Held a briefing on the revised Green Purchasing Guidelines (August 10)
  • Conducted supplier self-assessments (September to November)
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
  • Look into LCA*8 calculation for car models and products as well as a system and framework to achieve targets
  • Completed LCA calculation for car models and products, and set targets for 2040
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
  • Draft a plan concerning collaboraiton with NPO
  • Completed examination of collaboration with NPO
  • Continue to provide visiting education programmes (Tailored education programmes to meet the demand of local schools)
  • Provide visiting education programmes on the environment (2 schools)
  • Provided visiting education programmes on the environment (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
  • Systematically implement internal education through Toyota Boshoku Report, internal newspapers and monthly events
  • Posted articles about environmental activity information on Toyota Boshoku Report and internal newspapers.
    Held environmental lectures and activities on Environment month and Energy Conservation Awareness month
  • Systematically disclose environmental information
  • Disclosed information in as planned (CDP, etc.)
  • *6 Deca Bromo Diphenyl Ether (Fire retardant)
  • *7 Volatile Organic Compounds:Volatile Organic Compounds: 100 substances designated by the Ministry of the Environment
  • *8 Life Cycle Assessment: Overall assessment for total environmental impact of products from raw materials through to production, use and up to disposal