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Clean Vehicles from a Clean Plant |
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| Eco Mark on the rooftop of the plant |
The Motomachi Plant, which began operation
in 1959, produces the Crown and the Brevis, as well as ultra low-emission
hybrid vehicles (the Prius, Estima, and Crown), and has been promoting
environmental preservation activities based on the concept of "Clean
Vehicles from a Clean Plant." |
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| Challenge to Achieve Zero Combustible Waste as a Model Plant |
In
December 2000, the Motomachi Plant successfully eliminated the generation
of waste that must be sent directly to a landfill. As the next step,
the Plant General Manager issued a directive to completely eliminate
the generation of waste that must be sent to a landfill following
incineration. Since the Motomachi Plant was also designated as a model
plant for the company policy of "Challenge to Achieve Zero Combustible
Waste," the Zero Waste Emissions Promotion Committee was formed in
cooperation with other related departments. Focusing on measures to
eliminate waste generation at the source and effective utilization
through recycling, employees at the plant began taking actions toward
achieving the goal by the end of FY2003.
Kazuhiko Takarada, General Manager of the Administration Division,
stresses, "It is important for us to ensure that source-oriented measures
are implemented based on the Toyota Production System, which aims
to completely eliminate all wastage." For example, in the bumper painting
process, improvements in the bumper-setting jig have allowed electrostatic
spray guns to be positioned closer to the painting surface, thus reducing
wastage of paint. As a result, both the amount of paint used and waste
are reduced.
In order to effectively utilize waste as resources, the Motomachi
Plant set up Eco Stations to sort waste into some 30 different types.
A sorting manual was also created and registered on the intranet.
By simply entering the first letter of an item, a user can find the
name of the waste concerned and its designated disposal location at
a glance. The establishment of rules related to taking waste generated
by individuals home, and a system for reporting information on insufficient
sorting to the originating department, etc., are used to increase
the awareness of each employee.
Furthermore, approximately 230 suppliers of parts were asked to cooperate
by eliminating or reusing wrapping and packaging materials and switching
to recyclable materials, resulting in definite reductions in the volume
of waste generated. Thanks to these efforts and recycling measures,
the goal of achieving zero* combustible waste is beginning to look
achievable.
*Zero: Defined as a reduction of at least 95% from the level in FY1999 |
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Koichi Ina, Plant General Manager, reviewing the activities of the Zero Waste Emissions Promotion Committee |
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•Trend in Waste Generated
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•Reduction of Paint Usage through Improvements in Bumper-Setting Jig
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| Energy Conservation through Electricity Saving |
Electricity
accounts for 80% of the energy used at the Motomachi Plant.
Therefore, the plant is focusing on reducing its electricity
usage, which is equivalent to the amount used by approximately
20,000 regular households. As a source-oriented measure, mieruka
(visualization) of the hourly usage by each section and each
major line is adopted in order to encourage reduction of wasteful
electricity usage. Even when the plant is not in operation,
e.g., during holidays, energy conservation patrols check for
lights and pumps inadvertently left on. Through this kind of
steadfast daily management, coupled with facility improvements
based on ingenuity and creativity, the Motomachi Plant is making
progress in conserving energy.
In terms of facility improvements, after much trial and error,
the plant developed a tip-over type energy-saving pump that
utilizes gravity, thereby reducing air usage in the air pump
by 90%. This has contributed to reducing the electricity usage
of the compressor. A patent is pending for this pump, which
received the Karakuri Kaizen award from the Japan Institute
of Plant Maintenance. |
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•Structure of the Tip-Over Type Energy-Saving Pump
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| Support of Overseas Affiliates |
| The Motomachi Plant is a parent plant
to overseas production affiliates in Australia, Southeast Asia, India
and China, and is supporting these plants in both production and environmental
responses. Specifically, overseas employees who come to the Motomachi
Plant for training, etc., are introduced to the framework of environmental
management, best practices at the plant, and daily management statuses
through genchi genbutsu (on-site work experience). By implementing
the knowledge the trainees have gained from these experiences, each
affiliate increases its level of awareness. In this way, the Motomachi
Plant is helping Toyota implement its environmental measures globally. |
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[ Plant
Overview ]
•Location: 1, Motomachi, Toyota City, Aichi Prefecture
•Number of employees: 3,400
•Start of operations: August 1959
•Major products: Crown, Progrès, Brevis, Blit, Prius
•Site area: 1,600,000 m2
•Building area: 820,000 m2
•ISO 14001 certification: August 1997
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| [ 1 ]Activities in FY2002 |
•Major
Activities
(1) Activities, including community councils, to prevent legal
non-compliance and complaints
(2) Zero waste emissions activities
(3) Energy conservation activities
(4) Resource conservation activities (industrial use water and
oils and fats)
(5) Reduction of substances of environmental concern (VOC and
PRTR substances) |
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•Community Council Members Inspect the Plant
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•Controlling Waste Generation
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| [ 2 ]Environment-Related Accidents, etc. |
| •None |
•CO2 Emissions Volume
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•Volume of Waste Discharged
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| [ 3 ]Environmental Data |
•Air
Pollution Data (Conforming to the Air Pollution Control Law
and Prefectural Ordinances)
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•Water
Pollution Data (Conforming to the Water Pollution Prevention
Law and Prefectural Ordinances) |
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| 1. |
The control values are shown
in ppm for NOx, g/m3N for PM, and m3N/Hr for SOx. The
SOx item must follow the area-wide total pollutant control
stipulated in Aichi Prefectural Ordinances. |
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The actual measurements
of NOx and PM refer to maximum values with respect to
the control values for each particular target equipment |
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Note 1. The control
values for BOD and SS show the highest value (daily average)
Note 2. Discharged water volume unit: m3/day
Note 3. All figures are shown in mg/l, except for the pH item
Note 4. There are some other control parameters whose actual measurements
are below the N.D. level. They include the following: phenol, cadmium,
cyanide, organophosphorus compound, lead, chromium (VI) compound, arsenic,
total mercury, alkylmercury, polychlorinated biphenyl, total chromium,
trichloroethylene, tetrachloroethylene, dichloromethane, carbon tetrachloride,
1,2-dichloroethane, 1,1-dichloroethylene, cis-1,2-dichloroethylene, 1,1,1-trichloroethane,
1,1,2-trichloroethane, 1,3-dichloropropene, thiuram, simazine, thiobencarb,
benzene, and selenium.
Note that the abbreviations mean the following.
*pH: Hydrogen ion concentration
*BOD: Biochemical oxygen demand
*COD: Chemical oxygen demand
*SS: Concentration of suspended solids in water |
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•PRTR-Target Substances
*Unit: kg/year
*Volume removed: The volume of substances that are incinerated, neutralized,
broken down, or changed to other substances in the particular plant
*Consumption volume: The volume of substances that are changed to
other substances through chemical reactions, or are contained in or
accompanied with products and transported outside the particular plant
*Volume generated: The volume of substances that is generated unintentionally
*Landfill within site: The volume of substances disposed of as landfill
waste on the particular site |
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