Challenge of minimizing wastes produced in the Toyota Boshoku group

Basic approach

The Toyota Boshoku group verifies activities to reduce waste at each plant and deploys best practices across the organization such as reducing the defect rate and enhancing the recycling rate for components. We are also working on design and production preparations that realize a reduction in material loss rate.

Initiatives to achieve 100% in-process recycling in the door trim process

In the door trim manufacturing process at Toyota Boshoku’s Sanage Plant, we have been promoting in-process recycling of runners and defective products (referred to below as "waste materials") generated during manufacturing.
Currently, waste materials of the same material and color are sorted and 100% in-process recycling is implemented.
Having introduced new techniques and specialized recycling equipment that does not alter the color tone of waste materials comprising the same material but a mix of different colors, we are on track to achieve recycling, and are now moving forward with our implementation plan.
Going forward, we will continue promoting activities to achieve zero waste by ensuring 100% in-process recycling of waste materials, even if they are a mix of different materials.

Photo:Specialized recycling crusher capable of crushing only specific products
Specialized recycling crusher capable of crushing only specific products
Photo:General-purpose recycling crusher with air cleaning function that can crush a variety of products
General-purpose recycling crusher with air cleaning function that can crush a variety of products

Amount of waste