procurement and production - · pdf filefurther promotion of global toyota environmental...

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In order to promote environmentalmeasures through comprehensiveactions that include suppliers, Toyotaadopted the “Environmental PurchasingGuidelines” (hereafter referred to as the“Purchasing Guidelines”) and presentedthem to all of its suppliers of automobileparts and materials in March 1999, ask-ing for their cooperation regarding thefollowing items:(1) Voluntary actions aimed at enabling

each supplier to acquire ISO 14001 cer-tification by 2003

(2) Management of substances of environ-mental concern and provision of relateddata to ToyotaWith respect to (1) above, 98 compa-

nies successfully obtained certificationin FY2000. As a result, the cumulativetotal of certified companies now standsat 296 out of the 505 targeted compa-nies.

Further Promotion of Global Toyota Environmental Activities

Kousuke Shiramizu joined Toyota in 1963and has worked in a wide range of tech-nology and production areas since. Hebecame a member of the board of direc-tors in 1992, and has conducted activitiesfor establishing and improving theEnvironmental Management System, suchas ISO 14001, as a Director responsiblefor production environment. He became aSenior Managing Director in June 1999,taking charge of Environmental Issues andbecoming Chairman of the ProductionEnvironment Committee.

Kousuke ShiramizuSenior Managing Director and

Production EnvironmentCommittee Chairman

Executive Vice Presidentsince June 27, 2001

One of the major FY2000 achievements in the procurement area was the development ofthe “Environmental Purchasing Guidelines” in Europe and North America, which wereissued from the local business affiliates, resulting in major progress towards the creation ofa global structure.

In the production area, all of Toyota’s production plants and housing works achieved thegoal of “zero landfill waste” three years ahead of schedule. The FY2000 goal of stabilizingboth the total CO2 emission and CO2 emissions per sales unit to the 1990 levels, in a contin-uing effort to contribute to the prevention of global warming, was also achieved on schedule.

In order to globally expand coopera-tion with suppliers, each of Toyota’soverseas affiliates began the necessarypreparations for issuing the PurchasingGuidelines. Toyota, through each over-seas affiliate, requests the suppliers ineach country and region to follow over-

seas Purchasing Guidelines. Toyotacreates the basic policy and require-ments and presents them to its over-seas affiliates. The overseas affiliatesin turn create Purchasing Guidelinesthat are best suited to local conditionsand hold seminars to explain the guide-lines to their suppliers.

In North America, PurchasingGuidelines were issued in August 2000,and in the near future, suppliers therewill be asked to manage substances ofenvironmental concern related to Toyotaproducts. In April 2001, the PurchasingGuidelines for Europe were issued inconjunction with the start of operation ofthe French plant, and Toyota requestedcooperation from approximately 200suppliers. Toyota plans to graduallyimplement the Purchasing Guidelines inother regions as well, strengtheningcooperation with its suppliers overseas,as in Japan.

Toyota’s basicrequirements

(1) Acquisition of ISO 14001certification (EMAS* is alsoacceptable in Europe)

(2) Management of substancesof environmental concern relatedto products and production, andprovision of related data

(3) Provision of materialcomposition data related torecycling, etc.

Requirements specificto affiliates in

individual regions

Items Specified in the OverseasPurchasing Guidelines

Example:(1) Reducing packaging material(2) Transporting hazardous

materials, etc.

Procurement

Procurement and Production

Propagation of the EnvironmentalPurchasing Guidelines in Japan

Propagation of the PurchasingGuidelines Overseas and Issuancein Europe and North America

*EMAS (Eco-Management and Audit System):Voluntary EU regulation related to environmentalmanagement adopted by EU members, which tookeffect in 1995

Procurement and ProductionEnvironmental Report 2001

Production

29

In the procurement area, Toyota tookcomprehensive environmental mea-sures. By cooperating with its suppliers,Toyota reduced environmental risks,and controlled and reduced the use ofspecified chemical substances.

Strengthened the measures for environmental risk by buildinga communication structure and having each supplier assign aperson in charge of environmental management

Environmental risk reduction activities

Applicable to approximately 50 companies

Held seminars to explain PRTR1 Law compliance andreduction activities to raw material and supplementary materialsuppliers

PRTR Law-related activities


As part of the activities to reduce substances of environmentalconcern, Toyota held orientation seminars for its suppliers onthe importance of reducing hexavalent chromium

Hexavalent chromium reduction activities


Actions Taken in FY2000

In FY2000, Toyota began seriousefforts toward green purchasing2 target-ed at office supplies and office equip-ment such as personal computers.Toyota developed an internal criteria forbuying green products (e.g., productswith environmental labels), and hasbeen promoting actions to achieve a100% switch to green products.

(6) Volume of greenhouse gases2 emitted (1.72 million tons-CO2)

Volume ofwaste generated

Gases emittedinto the atmosphere

Released into waterways and soil

(8) Volume recovered as thermalenergy by Toyota (26,000 tons)

(9) Total volume of waste generated (525,000 tons)Volume reused (510,000 tons)Final volume disposed of (15,000 tons)3

(7) Total amount of wastewater (13.20 million m3)

Input

(1) Total material volume input (1.67 million tons)(2) Amount of material reused in automobile

production processes of Toyota (530,000 tons)(3) Total energy consumption (38.6 x 106 GJ)1

(4) Renewable energy consumption(Wind power generation: 346 GJ)

(5) Water consumption (16.6 million m3)

1. GJ (giga joule) = 109 J2. Greenhouse gas types Six types: CO2, CH4, N2O, HFC, PFC, SF6

3. Includes the ash generated from incinerators during recovery of thermal energy at Toyota

CO2: 1.70 million tonsGases other than CO2: 20,000 tons

The figure above captures the totalvolume of resources used duringToyota’s production process (input) andthe total volume of substances released(output) into the environment. InFY2000, a total of 1.67 million tons ofraw materials and supplementary mate-rials, a total of 38.6 x 106 GJ of energy inthe form of electricity, fuel, etc., and16.6 million m3 of water were used inToyota’s production activities.

Toyota emitted 1.72 million tons-CO2

of greenhouse gases into the atmos-phere, and released 13.20 million m3 ofwater into waterways. Of the total vol-ume of waste generated 26,000 tonswere recovered as thermal energy byToyota. Total waste volume came to525,000 tons, of which 510,000 tons(97% of the total waste volume) werereused.

1. PRTR: Pollutant Release and Transfer RegisterFor details see p. 30

2. Green purchasing: Toyota classifies the buying directly related toproduction as “procurement” and the buying ofoffice-related products and equipment as “pur-chasing”

Further Strengthening ofCooperation toward ComprehensiveEnvironmental Measures

Promoting Green Purchasing

Volume of Resources Input and Volume of Substances Releasedinto the Environment in FY2000

30

Based on the accumulated databaserelated to chemical substance manage-ment, Toyota established a PRTR1

Information Processing System jointlywith the Hitachi Group, and establishedEco Research Co., Ltd. (51% owned byToyota) in March 2001. Eco Research’sbusiness involves the appropriate man-agement of chemical substances andtechnical support related to PRTR. Forexample, using the Internet, it providesa unified MSDS2 management systemand chemical substance information tocompanies. Eco Research plans toestablish a comprehensive support sys-tem related to chemical substances bygradually implementing services likeenvironmental impact evaluation ofemission volumes, documentation ofchemical substances and the LCAanalysis system.

Environmental Information Network System

Consolidated environmentalmanagement

Tool for summarizing environmental actions and results at all Toyota consolidated companies, and for utilizing the collected information to provide quick feedback to the individual companies and share it among them

Management of Energy ConsumptionEstimation and Actual Results System

Energy management

Supports day-to-day energy conservation management by calculating the estimated energy consumption for each energy management section and comparing it to the actual usage

Prior Assessment System for Environmental Preservation

Chemical substancemanagement

Prior Assessment System for Environmental PreservationChecks the chemical components before a new raw material is adopted, decides whether or not the material should be used, creates a chemicalsubstance database, and links it to the procurement system

Shortens the prior assessment period, enables a quick decision on whether or not a substance may be used, enables paperless operations, and total management of composition data

Production Engineering Environmental Support System

Plant facility planning

Effectively supports environmentally considerate car designing by searching the Web for laws and regulations that are applicable to the equipment to be procured, and transferring application documents to the division in Toyota which is responsible for registration

PurchasingDivision

Supplier

(6) Purchase order issuance

(1) Information provision

(7) Delivery

(4) Prior assessmentresult transmission

(3) Priorassessmentanswer

(2) Priorassessmentrequest

Plant

(5) Product number registration

(4) Purchase request

Divisions planningto procure materials

Divisions responsible fortechnology management

Divisions responsible forenvironmental preservationDivisions responsible forsafety and health

Prior AssessmentDivisions

Plant Engineering Div.Safety & HealthPromotion Div.

Prior assessmentcomputerization rangeMaterial procurement system

Composition report

MSDS Test results

(wastewater, odors)Composition report

MSDS

Test results(wastewater, odors)

Production ControlDivision

Recent IT-related Actions

President Masahiro Higuchi at the Eco Researchfounding ceremony

In order to constantly improve envi-ronmental performance, building asystem that enables continuousimprovement activities is one of theimportant issues. In the productionarea, Toyota is taking steps to use IT asa practical and effective tool to carry outenvironmental management. Becausethe use of IT simplifies manual work,reduces the number of processes to bemonitored, and accelerates improve-ment in environmental performance,Toyota plans to develop more effectivesystems in the future.

As a specific example, in FY1999,Toyota began introducing the“Management of Energy Consumption

Estimation and Actual Results System”in the area of energy management, andimplemented this system for electricityuse at al l of i ts plants in FY2000.Toyota is also developing similar sys-tems for other energy types such assteam. Also in FY2000, Toyota workedon introducing the “EnvironmentalInformation Network System” for thepromotion of consolidated environmen-tal management, the “Prior AssessmentSystem for Environmental Preservation”related to the prior assessment of mate-rials, and the Environmental SupportSystem in the Production EngineeringDivision. Toyota plans to begin usingthese systems in FY2001.

Promoting the Use of IT in theEnvironmental ManagementSystem

Establishment of Eco ResearchCo., Ltd. in Support of PRTRActivities

1. PRTR (Pollutant Release and Transfer Register):Enacted as a law in 1999. Beginning in FY2001,businesses must document and report theamounts of applicable substances released ortransferred, to the government, which will thenpublish the collected results beginning in FY2002

2. MSDS (Material Safety Data Sheet):Data sheet that must be provided during anytransaction involving a chemical substance sub-ject to the PRTR Law


31

When introducing new raw materials,supplementary materials or when expand-ing its plants, Toyota conducts a priorassessment of the environmental impactincluding air, water quality, offensive odors,noise, vibration, waste and chemical sub-stances based on its Prior AssessmentSystem for Environmental Preservation.

In FY1999, the number of prior assess-ments conducted increased as a result ofthe addition of an electronic parts plant tothe Hirose Plant and others. However, inFY2000, the number decreased since therewere few plans to introduce new raw mate-rials or supplementary materials.

0

50

Air

100

150

’95 ’96 ’97 ’98 ’99 ’00 (FY)

200

250

300

350

400

500

450

266

364 357

291

Odor Water Noise Waste

480

294

Waste

Noise

Water

OdorAir

Num

ber o

f ite

ms

Items Evaluated by the Prior Assessment System for Environmental Preservation

With the goal of thorough prevention ofenvironmental impact, Toyota establishedthe Prior Assessment System forEnvironmental Preservation in 1984.Beginning in 1994, Toyota strengthenedchemical substance control and began oper-ating a system that can keep track of the tar-geted 2,232 chemical substances. Thesystem helps to understand “what chemicalsubstances were used and where, and inwhat quantities.”

To promote communication with the peoplein the surrounding communities, Toyota hasbeen actively promoting voluntary informationdisclosure. In FY2000, community councilswere formed in which three groups, Toyotaplant representatives, community representa-tives, and government personnel responsible forenvironmental issues, participated and helddialogs. In all Toyota plants and housing worksseminars were held ahead of the enactment ofthe PRTR Law and plant tours were conducted.

In the community councils, Toyota explainedits framework for chemical substances manage-ment, disclosed substance release data, andreported on environmental conditions, includingair and water quality, noise, vibration, offensiveodors, the actions being taken by the plants, aswell as complaint status. The responses fromthe community representatives who attendedthese community councils included, “Informationdisclosure to the surrounding communities isgood,” “I now have a better understanding ofchemical substances,” “The combination of themeeting with a plant tour helped me understandthe situation better.” Toyota plans to hold thesemeetings once a year in the future.

Consumption2

(14,700 tons)

Released intoatmosphere(5,060 tons)

Treated in plant1

(690 tons)

Recycled (1,400 tons)

Released into waterways(20 tons)

Chemical substances contained in raw materials and supplementary

materials(volume handled: 22,100 tons)

1. Treated volume refers to the volume of substances subject to PRTR that are incinerated, neutralized, decomposed, or changed to other substances through chemical treatment

2. Consumption volume refers to the volume of substances subject to PRTR that are changed to other substances through chemical reactions or are contained in or accompanied with products and transported outside the plant

Transferred as waste (230 tons)

Total Material Balance of Substances Subject to PRTR

Community council meeting held at Tsutsumi Plant

Furthermore, in FY2000, in response tothe PRTR Law, and to conduct global mea-sures that comply with the regulations ineach country in conjunction with the promo-tion of consolidated environmental manage-ment, Toyota revised the Prior AssessmentSystem for Environmental Preservation.Major revisions include the following:(1) increased the number of chemicals pro-

hibited for use from 149 to 457, whileincreasing the number of substancessubject to control, including evaluationof future toxicity, to 3,420

(2) prohibited the use of containers thatrequire to be disposed of in landfills

In FY2000, 38 substances subject toPRTR, totaling approximately 22,000 tons,were used at Toyota’s production plantsand housing works. Of this volume, 24%was released into the atmosphere or water-ways, or transferred out as waste. Data forindividual production plants and housingworks are included at the end of this report.

Toyota has been conducting emergencyresponse training as a part of preventivemeasures.

The facilities requiring emergencyresponses have been registered and regu-lar on-the-job training is being conducted.Concerning those facilities that may have aparticularly large impact on the environ-ment, simulations of emergency situationsfor training are held more than once a year,based on procedure manuals, and theseprocedures are confirmed and reviewedperiodically.

FY2000 Evaluation Results ofthe Prior Assessment Systemfor Environmental Preservation

Revision of the PriorAssessment System forEnvironmental Preservation

Thorough Implementation ofProactive Prevention Measures

Usage Status of SubstancesSubject to PRTR

Voluntary InformationDisclosure to LocalCommunities

Emergency Response Training

32

Since FY2000 was the last year of theSecond Toyota Environmental Action Plan,Toyota took actions striving to achieve thegoal of “stabilizing CO2 emissions volumeand emissions per sales unit at 1990 levelsby the end of FY2000.”

Some of the key actions that Toyota tookinclude the following:(1) streamlining the production system

through line integration(2) increase in efficiency of new lines(3) introduction of high-efficiency cogenera-

tion systems(4) self-wheeling1 of excess electrical power

These actions focused on improving pro-ductivity and measures for effective energyuse.

As a result, total CO2 emissions volumewas reduced by 13% from the 1990 levelwhile CO2 emissions per sales unit werereduced by 17%, achieving Toyota’s goalsin both cases.

In order to match its operation system tothe production load as in FY1999, Toyotaconducted line integration including trans-ferring RAV4 production from theMotomachi Plant to the Tahara Plant,thereby improving productivity and reducingenergy consumption.

In the installation of a new AZ seriesengine line at Kamigo Plant, Toyota tookadvantage of the know-how gained in theinstallation of the NZ series engine line inFY1999. Thorough energy-conservationmeasures were incorporated, such asdecreasing production processes (netshaping2), downsizing equipment, andreducing vehicle volume.

Furthermore, at the Kinuura Plant, main-taining a high operation rate from the startof CVT (continuously variable transmission)production significantly reduced the energyconsumption associated with introducing anew line.

Contributing to Preventionof Global Warming

In order to effectively utilize fossil fuels,Toyota has been actively promoting theintroduction of cogeneration systems,which offer higher energy conversion effi-ciency.

At the Hirose Plant, which was expand-ed in correspondence with an increase inthe production of electronic components, asystem with 7,500kW generation capacitywas introduced in conjunction with the plantexpansion plan. As a result, CO2 emis-sions were reduced by 2% despite theincrease in components production. Beforethe introduction of this system, the operat-ing situations of the existing boilers, heatingsources for air conditioning, etc. wereinvestigated in detail to ensure optimaloperation linkage to the new system.

( )

1,500

1,600

1,700

1,800

1,900

2,000

2,100

2,200

0’91’90 ’92 ’93 ’94 ’95 ’96 ’97 ’98

2,090

1,950

2,100

1,950 1,9401,900

1,950 1,950

1,870

1,780

1,700

(Thousand Tons)

Ene

rgy

usag

e vo

lum

e (

CO

2 em

issi

ons)

’99 ’00

Electricity

A-type heavy oil

C-type heavy oil

Kerosene

0.3817 kg-CO2/kWh

2.7000 kg-CO2/L

2.9419 kg-CO2/L

2.5308 kg-CO2/L

Butane gas

City gas

Coke

Coal

3.0094 kg-CO2/kg

2.3576 kg-CO2/m3

3.2502 kg-CO2/kg

2.3536 kg-CO2/kg

2

3

4

2.753.00 2.91 2.91 2.93 2.92

2.63 2.64 2.622.54

2.28

CO

2 em

issi

ons

per

sale

s un

it

Energy Usage Volume (CO2 emissions) CO2 emissions per sales

Energy Usage during Toyota’s Automobile Production Process and CO2 Emissions per Sales Unit

Tons/Billion Yen

(FY)*For CO2 emissions, CO2 equivalent values are now used instead of carbon equivalent values Conversion formula: (kg-CO2) = (kg-C) x 3.67

City gas 6%

Coal 0.9%

Kerosene0.1%

Coke 1%

Electricity66%

A-typeheavy oil17%

Butanegas7%

C-type heavy oil2%

Component Ratio of Energy Usedduring Automobile Production Process

0

10,000

Before After

20,000

30,000CO2 emissions (kg)

--- 65%

Effects of Process Set-up Time at Startof CVT Production at the Kinuura PlantPursuit of Production Activities

that Do Not Generate WasteStreamlining of ProductionSystem and Increase inNew Line Efficiency

Promoting the Introduction ofCogeneration and EffectiveOperation

1. Self-wheeling:Transmission of excess power to specific plantsites by leasing the electric power company’sexisting transmission lines

2. Net shaping:Forming parts from raw materials so that they canbe used without later machining processes suchas grinding and polishing


33

’92 ’93 ’94 ’95 ’96 ’97 ’98 ’99 ’00 (FY)

Ele

ctric

ity g

ener

atio

n ca

paci

ty

Vol

ume

of e

lect

ricity

gen

erat

ed

0

20

40

60

80

100

120(MW) (GWH)

100

150

50

0

200

250

300

350

400

450

500

44

106

163181

191

227242

294

328

430430430

51 5156

62 62

82

90

110

Electricity generation capacity

Volume of electricity generated

Capacity and Volume of ElectricityGeneration by the Cogeneration System

Existing facility Additional facility

Existing source Additional source

Flue firetube boiler Once-through

boiler

(Steam turbine)cogeneration

system

(Gas turbine)

(Wasteheat boiler)

Consumption(plant)

Supply source(motive power)

Heat source(absorption freezer)

Steam header Steam header

Heat source(absorption freezer)

Heat Source Supply Flow at Hirose Plant

To support wider use of green power,which reduces CO2 emissions by using nat-ural energy sources, Toyota became thefirst company in the automobile industry toparticipate in the Green Power CertificationSystem1 and concluded a wind power gen-eration subcontracting agreement. Based onthis agreement, Toyota will use 2 million kWhof wind-generated power per year startingin December 2001.

101

86

20.5 16.4

160160

143

164

127

161

110

142

89

130

58

126

55

134

53

136

117

54

31.9 33.9 33.9 31.627.7 27.7 27.1 27.8

120

80

40

3020100

40

’90 ’91 ’92 ’93 ’94 ’95 ’96 ’97 ’98 ’99 ’000

(FY)

25.2

4740

31

Vol

umes

of w

aste

and

scr

apm

ater

ial g

ener

ated

(Thousand Tons/Year)

Volume of Waste Generated and Scrap Material Generated Per Vehicle

Volume of wastegenerated

Volume of scrap material generated

Scrap materialgenerated per vehicle

45% decrease compared to 1990



(kg/vehicle)

Scra

p m

ater

ial

gene

rate

d p

er v

ehic

le

Toyota took actions striving to achieveone of the goals of the Second ToyotaEnvironmental Action Plan, “waste volumereduction by 75% compared to 1990 by theend of FY2000.” Through steady actionsand enhancement of activities designed toreduce waste generation at the source,such as the “5R Program”2 and the “ZeroLandfill Waste Program,”3 Toyota achievedits goals, reducing waste4 volume genera-tion by 78% and scrap material5 generationby 48% compared to 1990.

As electricity deregulation progressed inFY2000, Toyota signed a self-wheelingservice agreement with Chubu ElectricPower Co., Inc., enabling the power gener-ated by cogeneration systems to be effec-tively utilized among various plants, thusensuring the effective operation of thecogeneration systems Toyota owns.

Participation in the Purchase ofGreen Power

1. Green Power Certification System:In order to promote green power, a corporationcan subcontract the generation and supply ofwind power to Japan Natural Energy CompanyLimited, and receive a Certification of GreenPower indicating the amount of wind power beinggenerated

Reducing Waste

2. 5R Program:Activities to reduce waste at Toyota’s plants:the five Rs are Refine, Reduce, Reuse, Recycle,and Retrieve energy

3. Zero landfill waste program:A reduction in landfill waste generated directly byplants to less than 5% of the 1995 level

4. Waste:Total of waste subjected to intermediate treat-ment processes, such as incineration, and thosedisposed of in landfills

5. Scrap material:The total of all waste including that recycled forfree or for a fee. An index for evaluating thereduction of waste at the source

34

Toyota achieved its goal of “zero landfillwaste” by the end of FY2001 at vehicleassembly plants and by the end of FY2003for unit plants and housing works, wellahead of the original schedule, meeting thisgoal at all its plants and housing works byDecember 2000. This was made possibleby an all-company effort such as: - Project teams were formed under the

direction of the General Managers ateach plant

- The know-how and case studies from amodel plant were quickly propagated

- Employees came up with original andinventive ideas

- All employees participatedSpecifically, the promotion of reduction

of waste at the source, recycling by thor-ough classification and collection, and thedevelopment of recycled products usingwaste as resource were highly effective.As a result, Toyota’s resource reclamationrate has also been steadily climbing.

The Third Toyota Environmental ActionPlan includes the goal of “reducing com-bustible waste to 1/3 or less compared toFY1990 by the end of FY2005.” Toyotabegan working towards this goal in FY2001to achieve “zero combustible waste” usingthe Motomachi Plant as the model plant,and has been taking actions to completelyeliminate waste at the source.

Fue

l

3

7

8.4

3

≒03.6

Ash from incinerator 10

Intermediary processingby outside subcontractorIntermediary processingby outside subcontractor

Amount reduced

Tot

al w

aste

Com

bust

ible

Env

ironm

ent C

ente

r E

nerg

y re

cove

ry th

roug

hel

ectri

city

gen

erat

ion

Incombustible1

SubcontractorIsolated landfills External controlled type landfills

Company-controlledtype landfills26

31

1.4

Hazardous dry cell battery,hazardous dust, etc.

Harmless castingwaste, etc.

Hazardous dry cell battery,hazardous dust, etc.

Harmless castingwaste, etc.

Coal: 15RDF2: 11

Overview of Waste Disposal (FY2000 results) (Unit: Thousand Tons/Year)

Until recently, the spatter1, which getsscattered on the floor during the weldingprocess, had to be collected as refuse fromfloor-grooves and disposed of in landfills.

Toyota began working on achievingspatterless welding by setting optimal weld-ing conditions, e.g., modifying the weldinggun angle and optimal adjustment of thewelding current, and by improving pressaccuracy, and succeeded in reducing thevolume of spatter from 60 tons/year to 10tons/year at the Tsutsumi Plant.Furthermore, this 10 tons/year of spatter isrecycled as a raw material, and actions arebeing taken to achieve spatterless weldingat all Toyota lines.

In painting processes, Toyota has beenworking on reducing waste paint and wastethinner. At the Takaoka Plant, a newlydeveloped cartridge method paint systemwas introduced, significantly reducing lossduring color changes.

The Total Wastewater TreatmentCenter uses a biochemical treatmentmethod, which uses microbes for removingorganic matter. The organic sludge gener-ated when these microbes multiply used tobe extracted and disposed of as waste.However, an ozone oxidation equipmentwas added to the wastewater treatmentprocess, reducing the volume of the organ-ic sludge generated. This improvement,along with other measures, reduced the

Before improvement After improvement

Achieves zero organic sludge generation by having the ozone oxidation equipment biologically decompose the multiplied microbes, and circulating them back to the aeration2 tank as nutrients.

Oil separation

Aeration tank

Reactiontank

Circulation

O3 generator O2 generator

No sludge tobe removed

Compressor

Settlingtank

Sandfiltration

Pump

Sludge Reduction Using an OzoneOxidation Equipment

1. Spatter:Powder resulting from the sparks generated whensteel powder burns during the welding process

volume of wastewater sludge from 10,000tons in 1999 to 7,500 tons in 2000.

1. Incombustible:Reduction by 77% compared to 1999 due to achievement of “zero landfill waste” by plants and housing works

2. RDF (Refuse Derived Fuel): Solid fuel derived from waste

Achieving Zero Landfill Waste atAll Plants and Housing Works

Reducing Waste at the Source

■ Welding Process with Significantly Reduced Spatter

2. Aeration tank:Biological treatment tank for removing organicmatter from wastewater; supplies the oxygenneeded for microbial activity


35

Volume of WasteGenerated31,000 tons

Wastewatersludge

24%

Paperwaste13%

Paint-related

12%

Waste oil11%

Casting-related2%

Plasticwaste19%

Other19%

Volume of Waste Generated in FY2000: Breakdown

100

90

95

80

85

0

’90 ’92 ’94 ’96 ’97 ’98 ’99 ’00

Rec

lam

atio

n ra

te (

%)

96.2

Reclamation rate

liability recycling + contracted recycling + marketable recycling

total waste + liability recycling + contracted recycling + marketable recycling100

Changes in Reclamation Rate

(FY)

Toyota evaluates (1) substances thatare released in large volumes, (2) sub-stances that are highly toxic, and (3) sub-stances whose risk exceeds internalstandards. Toyota also has been workingto reduce toluene and xylene, substanceswhich are subject to PRTR and arereleased into the atmosphere, as well asnickel which is discharged into waterways.

Toluene and xylene, which account forthe majority of VOCs (Volatile OrganicCompounds) generated at Toyota, are themain ingredients of paint thinners, majorityof which are generated from painting

processes. Toyota began using thinnerswith lower toluene and xylene contents andintroduced a new painting system into thepainting line at the Takaoka Plant.

The new painting system uses the fol-lowing:- Water-based paints with low environ-

mental impact- Cartridge method painting system that

reduces paint loss during color changesand significantly reduces purge thinnerusage

- Painting robots that can paint withoutany wasteThe new paint system thereby estab-

lished a technology that reduces VOCemissions to 35g/m2 in FY2000 in a mass-production line. Toyota plans to expandthe application of this new technology tothe painting lines at other plants in thefuture.

’97 ’98 ’99 ’00

65 64

5560

50

40

0

70

Em

issi

on v

olum

e

(g/m2)

53

Trend in VOC Emissions Volume

(FY)*Due to a recalculation of VOC emissions volume for FY1999, the value of 53g/m2 reported in the 2000 Environmental Report has been corrected to 55g/m2

Car

trid

ge

(3) Electrostatic painting

Painting robot Automobile body

(2) Cartridge carrier

(1) Filling paints

An Innovative System of Electrostatic Painting Using Water-based Paint,the Cartridge Method and New Painting Robots

Nickel is contained in paint primers andplating processes, and most nickel waste isgenerated in painting processes. Toyota isworking on reducing nickel discharge vol-ume by (1) developing supplementarymaterials not containing nickel, and (2)treating wastewater containing nickel.Since the development of supplementarymaterials takes time, Toyota introduced achelating* coagulation process, whichemploys a chelating agent to cause thenickel contained in wastewater to coagulateand settle, for use in the wastewater treat-ment plants at applicable plants. As aresult, the nickel concentration in thewastewater at these plants was reduced to0.1mg/L or lower.

Toyota is safely storing end-of-life trans-formers containing polychlorinated biphenyl(PCB) as part of an insulating oil, in accor-dance with the standard specified by law.Measures have been implemented to pre-vent leakage, soil contamination, or theescape of evaporated gas, in the unlikelyevent of a leakage. Currently, Toyota has3,146 transformers in storage.

*Chelating agent:Chemical that reacts with and causes nickel tocoagulate

Reducing Substances of Environmental Concern

Reducing VOC Emissions

Reducing Nickel Discharge

Storing PCB

36

Toyota not only thoroughly maintainsand preserves the facilities and equipmentthat use water, but is also trying to com-pletely eliminate unnecessary water usagethrough daily management. In particular,vehicle assembly plants, which have paint-ing processes that use a lot of water, haveset up a goal of “reducing water usage perunit produced by 20% from the FY1995level by the end of FY2005.” Towards thisgoal, they have investigated the processesthat use water, installed water meters tograsp actual usage, and are developingaction plans based on these results.

’95 ’96 ’97 ’98 ’99 ’00 (FY)0

1

2

3

4

5

6

7

8(m3/unit)

6.6 6.3 6.57.0

6.16.6 6.3 6.5

7.0

6.15.4

Trend in Water Usage in the FourVehicle Assembly Plants

Other Environmental Data

Data on the results of activities concern-ing atmospheric and water pollution has

Yea

rly e

mis

sion

am

ount

Trends in Amount of Nitrogen and PhosphorusEmissions Included in Wastewater

180

(Tons)

160

140

120

100

30

20

10

0’95 ’96 ’97 ’98 ’99 ’00 (FY)

21

128 126

2330

119

1712

119101 83

7.4

Nitrogen Phosphorus

Trends in Amount of Sulfur Oxides Emissions

1000

800

600

400

200

100

0’95 ’96 ’97 ’98 ’99 ’00

251212

177 187 173 184

(1,000 m3N)

(FY)

Am

ount

of S

Ox

emis

sion

s

Trends in COD of Wastewater

250

200

150

100

0’95 ’96 ’97 ’98 ’99 ’00

CO

D e

mis

sion

vol

ume

(Tons)

(FY)

151

171 174

119110 107

’95

Groundwater

’96 ’97 ’98 ’99 ’00 (FY)

(Million m3)Plant-usewater

Tapwater

15.5

2.02.2 2.4 2.3

2.3

2.2

16.0 16.1 16.2 15.3 14.2

0

2

4

6

8

10

12

14

16

18

20

0.7 0.7 0.5 0.4 0.2 0.20.7 0.7 0.5 0.4 0.2 0.2

Trend in Total Amount of WaterUsage in Vehicle Assembly Plants

also been included. Data on COD* wasalso added beginning FY2000.

In order to reduce organic matter, nitro-gen, and phosphorus, which causeeutrophication, Toyota has been promotingmeasures such as reduction of the use ofraw materials and supplementary materials,and development of alternative materials.

By adding denitrification facilities forremoving nitrogen from untreated waste-water to the Total Wastewater TreatmentCenters at four parts plants from 1998 to1999, Toyota succeeded in reducing thenitrogen content of the wastewater byapproximately 20% in FY2000.

Toyota also reduced phosphorus, forexample, by modifying the coagulation sed-imentation conditions at the primary waste-water treatment facil i t ies for paintingprocesses.

BOD oxidationtank

Nitrificationtank

Scope of additional measures

Return flow of sludge

Denitrificationtank

Chemical

Sedimentationtank

Untreatedwastewater

*Principle: Nitrogen in untreated wastewater is oxidized into nitric acid, etc. in the nitrification tank, which is then reduced by a chemical added in the next denitrification tank into nitrogen gas. It is then removed from the wastewater and dispersed into the atmosphere

Denitrification Process Flow

Conserving WaterResources

Measures to Prevent Eutrophication of the Ise Bay

* Water released into rivers from the plants and housingworks in Aichi prefecture flows into the Ise Bay

*COD (Chemical Oxygen Demand):One of the indices that express the amount oforganic matter in water


In 1992 there were no environmentalstandards on soil or ground water availablein Japan. So Toyota began studying theinvestigation technologies and the status ofremediation technologies used in Europeand the U.S., and since then has been tak-ing active measures. By May 1996, soilsamples had been taken at approximately10,000 locations and groundwater sampleshad been taken at approximately 200 moni-toring wells inside and outside the buildingsin 12 plant sites. The results showed that

37

Although in the past Toyota has usedthree chlorinated organic solvents, whichare known for causing contamination in soiland ground water, it has already completelyphased out their use. Trichloroethylenehas been widely used since the 1950’s bymany industries, uninformed of its haz-ardous nature. Toyota had phased out itsuse in August 1989, even before it wasdesignated as a hazardous substance bythe Japanese government in October ofthat year. Toyota also phased out the useof 1,1,1-trichloroethane in July 1995 anddichloromethane in March 1997. Toyotahas been voluntarily investigating theeffects of pollutants on soil and groundwater within its plants and housing workssince 1992, and has been implementingremediation measures in contaminatedareas and reporting the facts to both thegovernment and the surrounding communi-ties.

trichloroethylene was present at concentra-tion levels between less than 0.002 and0.93mg/L in soil and between less than0.002 and 3.63mg/L in ground water at sixplants, i.e., Honsha, Motomachi, Kamigo,Takaoka, Miyoshi, and Tsutsumi. Cis-1,2-dichloroethylene, which is generatedthrough the biological decomposition oftrichloroethylene, was found to be presentat concentration levels between less than0.004 and 1.84mg/L in ground water. Soilcontamination by 1,1,1-trichloroethane wasconfirmed at one location, but the level inground water was below environmentalstandards. The dichloromethane concen-tration levels were also below environmen-tal standards in both soil and ground water.

Target Substances and Discontinuation Timing

Targ

etS

ubst

ance

App

licat

ion

Alte

rnat

ive

met

hod

Disc

ontin

uatio

ntim

ing

Trichloroethylene1,1,1-

trichloroethane Dichloromethane

Degreasing andcleaning of parts

Degreasing andcleaning of parts Cleaning of jigs

Alkaline cleaning,etc.

Vacuum degreasing,etc.

Alkaline cleaning,etc.

August 1989 July 1995 March 1997

Plant Level

Soil Ground water

Trichloroethylene MeasurementValues in FY2000

Environmental standard: 0.03 Unit: mg/L

Honsha less than 0.002 - 1.50 less than 0.002 - 2.88

Motomachi less than 0.002 - 2.43 less than 0.002 - 2.61

Kamigo less than 0.002 - 0.72 less than 0.002 - 2.58

Takaoka less than 0.002 - 0.96 less than 0.002 - 3.09

Miyoshi less than 0.002 - 2.64 less than 0.002 - 2.64

Tsutsumi less than 0.002 - 2.46 less than 0.002 - 1.14

1. Measurements are taken at all plants and housing works2. Has not been detected in plants other than those listed (At the three housing business sites, measurements began in 1997)3. The level has a range since each plant includes multiple

measurement points

Soilremediation

facility

Soil

Ground water

Barrier-typewell

Groundwaterremediation

facility

P

Soil and Groundwater Remediation Measures (conceptual)

Based on the investigation results,Toyota developed a remediation plan andhas been remediating soil using soil vaporextraction method1. Approximately 70% ofthe areas have been remediated so far,with the remaining areas scheduled forcompletion by the end of FY2001.

In January 1999, Toyota voluntarilyreported its remediation measures, etc. tothe government, and has been reportingthe remediation status on a regular basis.Beginning in 2000, ahead of the enactmentof the PRTR Law, Toyota has been publi-cizing discharge volumes of chemical sub-stances and explaining the environmentalimpact evaluation results according to dis-charge volumes of chemical substances ateach of its plants and at community coun-cils to promote communication with peoplein the surrounding communities. In April2001, Toyota’s efforts related to soil andgroundwater remediation were alsoexplained.

In terms of groundwater contaminationprevention, Toyota put the highest priorityon preventing the contaminated water fromflowing outside company sites, and adopt-ed barrier-type wells and a pump and treattechnology2 using aeration equipment. In1997, Toyota completed an effluent preven-tion measure, which involved the digging ofbarrier-type wells along the downstream

perimeters of its plant sites and pumpingand remediating the ground water fromthese wells. In some cases, this effluentprevention measure altered the flow ofground water, resulting in higher pollutantconcentrations than the initial measurementvalues observed within company sites.However, after soil remediation is complet-ed by the end of FY2001, the contamina-tion levels of ground water are expected todrop as the migration of pollutants from soilto ground water will stop. By the end ofFY2000, Toyota had invested approximate-ly 8.5 billion yen in soil and groundwaterremediation measures.

Soil and Groundwater-related Measures

Early Implementation ofInvestigation andCountermeasures

Approximately 70% of SoilRemediation Completed

Voluntary Information Disclosure

Groundwater ContaminationPrevention Measures Complete

1. Soil vapor extraction method:Draws out the organic solvent gases inside conta-minated soil and removes them through activatedcarbon adsorption

2. Pump and treat technology:Pumps out ground water, gasifies and separatesorganic solvents by atomizing the water and blow-ing air into it from below, and removes themthrough activated carbon adsorption

Plant Initiatives (1)

Miyoshi Plant Environmental Responses Linked to MVP Activities

Setting its Own High Standards and ImplementingEnvironmental Measures

The Miyoshi Plant, with about 1,500 employees, began operating in1968 as a plant manufacturing chassis parts. It produces parts such aspropeller shafts, steering columns, and constant velocity universal joints.In particular, it has a capacity of producing approximately 2 million pro-peller shafts annually and is a major production base accounting for about80% of Toyota’s supply.

The Miyoshi Plant is currentlyengaged in MVP activit ies1,which are intended to increaseits capabilities and vitalize itsorganization by establishing indi-vidual goals in areas such asproduct quality, safety and costs,and making efforts to achievethose goals. The plant is alsolinking these efforts to environ-mental measures and is settinggoals that are higher than com-pany-wide level and working toachieve them.

Plant General Manager Shuhei Toyodachecks the start-up of the cogeneration

system

Introduction of New Technology and FullParticipation to Reduce CO2 by ThoroughlyEliminating Muda (waste)

In FY2000, CO2 emissions from the Miyoshi Plant were 62,000 tons, a27% reduction from the 1990 level and well below the goal of 76,000 tons.This was in part the result of the introduction of a cogeneration system.The plant has succeeded in increasing the efficiency of cogeneration bysupplying, with priority over electric power generation, the steam generat-ed by waste heat boilers to the heat treatment process, which requireshigh volumes of steam.

As a result, the Miyoshi Plant was able to shut down one of its threeboilers used for generating steam and can supply 70% of electricitydemand through cogeneration, cutting CO2 emissions by 10,000 tons.*For CO2 emissions, CO2 equivalent values are now used instead of carbon equivalent values

2. Air blow:Using compressed air to blow off moisture and other substances on machined parts

3. Oil mist supply air:Air used to supply lubricating oil to the bearings of rotating shafts

38

1. MVP (Miyoshi Valuable Profit Center) Activities:Activities intended to make the Miyoshi Plant a business with higher added value (profitability)

Making the volume of air leakage from replacement parts visible toenhance operators’ environmental awareness

Steering column assembly

GG

Air for combustion Steam sent to plantFuel Electric power Electricity

Exhaust gas

Steam

CondenserGas turbine

Waste heat boiler Steam turbine

Structure of the Miyoshi High-efficiency Cogeneration System

In addition, the plant is takingaction to thoroughly reduce thevolume of wasteful compressedair used. “Any air compressiontaking place other than duringmachine operation” is defined asan “air leak.” Steady activities are taken which cover not only daily man-agement tasks, including air-leak patrols and repairs, but also simultane-ous inspections on holidays intended to locate air leaks and prevent themoccurring repeatedly. The plant attempted to eliminate all Muda (waste)by taking equipment-related measures such as: using smaller-diameterair blow2 nozzles, decreasing the duration of blow, and discontinuing theoil mist supply air3 when the equipment is in standby mode. In conjunc-tion with prior activities, this enabled one of the four 950kW compressorsused as air supply sources to be shut down, resulting in a 1,200 tonreduction in CO2 emissions.

MVP: Miyoshi Valuable Profit Center


Miyoshi Plant, Adjacent to ResidentialNeighborhoods, Puts Top Priority on the LocalEnvironment

According to Yoichiro Harada, an environmental preservation manager,“preventing any irregularities and complaints is one of our key jobs andresponsibilities to the local community.” The Miyoshi Plant lies adjacent toa residential district, so it pays close and detailed attention to the effect ithas on the local area.

To take water quality as one example, the plant internally manufactureda device, named “Mihari-kun,” to detect irregular wastewater that can havea detrimental effect on water processing functions and installed it at wateroutlets in every building to assist in the early detection of problems at thesource.

In addition, prior to the installation of the cogeneration system, the plantperformed detailed analysis using computer simulations in order to imple-ment sound and vibration countermeasures to prevent any effect on thesurrounding areas. The plant also conducted regular patrols at the siteproperty lines for early detection of sensory pollution such as noise andoffensive odors.

In order to gain the understanding of the local residents, each year theplant invites the heads of each ward for a plant tour and discloses corpo-rate information to community councils. In an effort to keep the local envi-ronments beautiful, the Miyoshi Plant also participates in beautificationactivities carried out in its neighborhood, as well as in the Miyoshi Pondcleaning activity organized by Miyoshi Town.

In order to increase the efficiency of equipmentenergy use, the plant has integrated its equipment — mainly in the heattreatment process — to low-load facilities. By modifying temperature con-ditions and materials based on innovative arrangements of heat-treatedparts, the plant has been able to consolidate approximately 50 heat treat-ment furnaces, thereby reducing CO2 emissions by 2,000 tons.

Educational activities are an important part of raising environmentalawareness. The Miyoshi Plant works hard to raise awareness concerningthe environment in order to strengthen environmental preservation activi-ties with participation from all employees through measures such as hold-ing the Environmental (Energy Conservation and Zero Emissions) Fair.

39

Promoting More Effective Use of ID Sheets toAchieve Zero Waste of All Types

One important tool usedto support the MiyoshiPlant’s “zero landfill waste”activities has been the “IDSheet,” a type of wasterecord. The plant conductsthorough investigations ofall waste and determinesthe processing or disposalmethod based on a determi-nation of the sources andcomposition. The results are systematized and indicated on ID Sheets,and by implementing thorough sorting at the source, the plant was able toachieve zero landfill waste ahead of schedule.

The plant has now set as its goals to achieve the following by the endof FY2003:(1) eliminating the generation of all waste(2) a 50% reduction in scrap materials by implementing measures at the

sources where the waste is generatedAs a first step, classifying of waste will be further strengthened. In

order to implement classification suitable for each source and to clarifymanagerial responsibilities, the outdoor resource stations used in the pastwere eliminated and new stations that increase classification from 11 dif-ferent types to a maximum of 20 types by groups were installed.Moreover the new station allows waste volume calculation by group. Theplant through its extensive activities is promoting waste reduction at itssource and recycling through effective use of the ID Sheets.

Water detector Mini-computer

Light projector Light receiver

Sewage outlet Sewage inlet

The opacity of the incomingwater is detected from changesin the volume of lightthat passes through.

Out

goin

g sig

nalPrinciples of Mihari-kun

Environmental (Energy Conservationand Zero Emissions) Fair held in

February 2000

ID Sheets

Indoor group resource station andresource collection vehicle

’98 ’99

7474

’00 (FY)

60

0

65

70

75

80(Thousand Tons)

78

62

Trend in CO2 Emissions

1.6

1.4

1.2

0

1.2

1.4

1.6

1.8

Trend in Waste Volumes Generated

’98 ’99 ’00 (FY)

(Thousand Tons)

ToyotaCity

ShizuokaPrefecture

AichiPrefecture

MiePrefecture

Toyota Head Office

Miyoshi Plant

Promotion of Absolutely Clean Wastewater and Activitiesthat Contribute to the Local Community

Integrated Manufacture of Drive Train PartsStarting with Raw Materials

The Kinuura Plant, which islocated in the waterfront industrialarea on the Kinuura Bay, beganoperations in 1978 as a plant man-ufacturing drive train parts. Today,its 2,500 employees manufacturetransmissions, constant velocityuniversal joints, continuous variabletransmissions (CVTs), and otherparts. The Kinuura Plant conductsintegrated production of drive trainparts starting with raw materialsincluding machining and assembly,and accounts for 24% of Toyota’stotal transmission production(110,000 units per month). The fin-ished products are supplied toJapanese plants as well as over-seas vehicle assembly plants andunit plants.

The grinding residue generated duringmachining processes is processed as wastewith a water content of approximately 40%.In order to prevent residue from sinking tothe bottom of tanks, the Kinuura Plant devel-oped a new coolant device, for which apatent has been acquired, that uses excessflow to make it float and wash away. By also

using a high-performance water separator, the water volume was reducedand the amount of grinding residue reduced from 420 tons to 360 tons.

For the forging process, the plant also switched to a mold lubricant1,which is high in wastewater processing performance and installed addi-

One feature of environmental measures at the Kinuura Plant is“achievement of thoroughly clean wastewater as a top priority,” accordingto Akira Takahashi, an environmental preservation manager. TheKinuura Plant, which discharges processed water into the Kinuura Bay,has undertaken actions with an emphasis on clean wastewater since itwas established. Since the plant is located adjacent to a marine areawith strict COD standards, Toyota installed at the plant its first wastewatertreatment center that utilizes an activated sludge treatment system withcontinuous activated carbon absorption system. In order to implementthorough preventive measures, the plant pays close attention to numer-ous details including separation of storm drains from roads and frombuildings and accumulation of rainwater that is mixed with oil from road-ways so that it can be cleaned at the wastewater treatment plant.

If an irregularity should occur, responses and safety structures are inplace. Each year a local committee (“Kinuura Harbor Oil Spill Preventionand Countermeasures Committee”) participates actively in the oil spillprevention training conducted under the guidance of the Japanese CoastGuard. The expertise acquired from this is particularly useful for the train-ing conducted regularly within the plant. In addition to day-to-day man-agement and inspections, environmental patrols are performed regularly,even on holidays, in preparation for accidents.

In implementing clean wastewater, raising awareness concerning theimportance of water is essential. The Kinuura Plant also engages inactive reuse of processed water in order to increase understanding of theimportance of water through creative innovations. Of the 2,200 tons ofwater processed each day, approximately 10% is used in toilets and forwatering trees and plants.

High-performancewater separator

Grinding residueafter removal of water

Circulatingfiltration

Frommachinery

Water flow agitation

Tomachinery

P P

Structure of the New Excess Flow Coolant Device and New Water Separator

1. Mold lubricant:A lubricating agent that makes it easy to remove forged items from molds40

Achieving Thoroughly Clean Wastewaterthrough Preventive Measures

Reducing Waste such asSludge from Water

tional cleaning equipment to reusethe mold lubricant, so that the volumeof waste fluid and wastewater andsludge generated have both beenreduced.

Toyota installed its first ozone oxi-dation device2, a new technology, atthe wastewater processing plant.Since microorganisms are affected bydecreases in the water temperature,the plant had considerably difficulty insetting the operating conditions dur-ing winter, but these problems wereovercome and a device that could bedeployed at all plants was completed.As a result of these improvements,sludge was reduced from 1,200 tons to 870 tons.

Plant General Manager Yoshito Kato observes oil fence installation training

3.1

2.1

1.4

0

1.0

2.0

3.0

4.0

Reductions in Waste Volumes

’98 ’99 ’00 (FY)

(Thousand Tons)

Plant Initiatives (2)

Kinuura Plant

2. Ozone oxidation device:A device that uses ozone to decompose microorganisms See p. 34


In 1998, the Kinuura Plant was awarded the Chubu Bureau of InternationalTrade and Industry, Director General’s Award for “Plants with excellent energymanagement (Thermal Category),” for its reductions in CO2 emissions throughenergy consumption reduction and energy conservation.

In FY2000, a switch was made to an alkaline rinsing agent that can beused at room temperature during heat treatment processes and the use ofsteam heaters to heat up items was terminated. In addition, indoor air wasgenerally used for turbo compressors, but a trial at using lower temperatureoutdoor air was implemented and positive results obtained. So all units weremodified to use outdoor air, resulting in a reduction in CO2 emissions of 320tons annually.

In order to raise awareness concerning energy conservation, a wide rangeof unique ideas have been introduced. The volume of air used is convertedinto cost and displayed on an electric signboard in real time on the aluminumdie casting and forging lines. The manager in charge of facilities has beennamed the “minister of energy” and his name displayed to raise awareness ona day-to-day basis.

Seeking to Be a Plant Trusted by the LocalCommunity

In order to facilitate communication with local residents, 16neighboring companies established a “No. 4 District CompanyLiaison Committee,” which acts as a liaison with 12 local neigh-borhood associations, makes periodic reports, and conducts planttours. The Kinuura Plant holds plant tours and discloses PRTR

information to publicize the plant’s environmental activities andpromote understanding of those activities.

In addition, the Kinuura Plant participates frequently in localactivities including the region’s largest obon dance festival (one ofJapanese summer festivals), a source of great pleasure to thelocals. One activity that has been going on for 10 years is the “vol-unteer farm” using borrowed land near the plant. During the har-vest time, persons from local welfare facilities are invited to thevolunteer farm to enjoy the organically grown vegetables and abarbecue. Of course, all maintenance work from cultivation tosowing, weeding, and watering is performed by volunteer employ-ees. An employee in the Volunteer Office says, “when we receivea thank you letter, all the labor of weeding in the summer is forgot-ten. I hope that this type of a project, which makes the local resi-dents happy, will be continued.”

Harvesting at the volunteer farm

Incorporating Ideas into Raising Awarenessabout Energy Conservation

A “Minister of Energy” display plate

Air usage volume is converted tocost and displayed on an electric

signboard (yen/hour)

ToyotaCity

ShizuokaPrefecture

AichiPrefecture

MiePrefecture

Toyota Head Office

Kinuura Plant

41

Assembly of a CVT pulley

A plant tour conducted by the Liaison Committee

’98 ’99

161

’00

152

(FY)

150

0

160

170

180

173

Trend in Reductions in EnergyUse (CO2 Emissions Volume)

(Thousand Tons)

*For CO2 emissions, CO2 equivalent values are now used instead of carbon equivalent values

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