August 17, 2012
Energy Huntsville Forum
1
Toyota Manufacturing in North America
CAPTIN
1985
Vehicle Plants - 7
TMMC 2
2008
Unit Plants - 5
TMMC
1988
Engine Plants - 2
Regional HQ
TABC
1971
BODINE
1990
SIA
2007
TMMI
1999
BODINE
2005
TMMBC
2004
TMMMS
2011
TMMTX
2006
TEMA
1996
TMMWV
1998
TMMK
1988
TMMAL
2003
$21+ Billion Invested
40,000 Direct Employees
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TMMAL Overview – Company Profile
Foundation: June 1, 2001
Investment: $700 million (by Spring 2014)
Location: Huntsville, AL
Toyota Property Line
NEW
3.5L V-6
Plant Size: Land 200 acres
Building 1.08 million sq ft
Employees: 1,150 (by Spring 2014)
4-Cyl
4.0L V-6
5.7L &
4.6L V-8
1GR E/G （V6 4.0L）
3UR E/G （V8 5.7L）&
1UR E/G (V8 4.6L)
1AR FE（2.7L）&
2AR FE (2.5L)
146,000/yr
144,000/yr
216,000/yr
SOP
Aug. '05
Dec. '06 (3UR), March '09 (1UR)
Sept. '11
Stats
24 valve 245 HP
32 valve 381 HP /
32 valve 310 HP
16 valve 182 HP /
16 valve 178 HP
Customers
TMMBC, TMMTX
TMMI, TMMTX
TMMK, TMMC, TMMI, SIA
Engines
Capacity
3
What Makes Toyota Different?
• Empower Team Members
• What Gets Measured Gets Done
• Never Stop Improving
4
TMMAL Environmental Team
What is the Environmental Team?
•
•
•
Provides support, guidance and
standardization
Team Member-driven
Environmental system/program
Follows annual calendar for
activities, training and audits
Who is on the Environmental Team?
•
•
•
Voluntary position
2 per Group House – 1 per shift
Serve at least one year, many
serve longer if trained as Internal
Environmental Auditor
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Regular Environmental Activities
Process Checks
DAILY
Kamishibai Checks
WEEKLY
Team, Management
Meetings
MONTHLY
Audits
SEMIANNUAL
Kaizen Blitz
SEMIANNUAL
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Daily Process Checks
•
•
•
Production Team
Members check their
process daily at start
and end of shift
Report any issues or
concerns for compliance
or risk
Enables management,
Environmental Team
Members to quickly
address issues and
implement
countermeasures
Right: Mist
Collector
Machining
Process
Below: Daily
Checksheet
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Kamishibai Checks
紙芝居 = “paper drama”
•Form of Japanese storytelling
•Often shared with elementary-age
children
•
Use card system and board
for audit tracking
Environmental Team
completes weekly audit on all
items in daily checks
•
–
–
–
•
Managing your process
Compliance and risk
Knowledge retention
Ensures production Team
Members are completing
daily checks accurately
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Team & Management Meetings
•
Monthly Team meeting to:
–
–
–
•
Share targets and results
Communicate new requirements
Highlight special events
Provide monthly status
update to upper management,
address any specific issues
raised in Monthly Team
Meeting
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Semiannual Environmental Audits
•
Specially-trained group of auditors within
Environmental Team
•
Conduct semiannual audits to confirm system health.
Look for:
–
–
Compliance and risk management
Training records and document control
•
Face-to-face interviews with randomly selected team
members on environmental awareness topics
•
Auditors responsible for multiple areas in plant, but
can’t audit own area
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Semiannual Kaizen Blitz
KAIZEN – Continuous Small Improvement
BLITZ
– Hitting it from all directions in a
concentrated effort!
Cross functional team focuses on improvements in
specific environmental impact areas:
– Energy
– Water
– Waste
– Special Projects
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Semiannual Kaizen Blitz
•
Corporate offices provide target reduction
percentage, TMMAL calculates identified
savings for next year
•
Potential kaizens placed on following FY’s
Environmental Management Plan
–
TMMAL currently working on items identified in FY12
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Semiannual Kaizen Blitz
FY12 Energy Reduction
1,400,000
Kilowatt Hours
1,200,000
1,175,400
283,500 kwh,
$19,845
annual
savings using
compressed
air actuators
in production
areas
1,000,000
800,000
600,000
400,000
200,000
1,069,532 123,662
kwh,
$8,656
annual
savings
by
replacing
outside
lighting
0
Target
Actual
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Semiannual Kaizen Blitz
Compressed Air Actuators
13 valves not being
used in production areas
• 63 hours/week
• Estimated Annual Savings:
– 283,500 kwh/year
– $19,845 / year
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Semiannual Kaizen Blitz
Old
Outdoor Lighting
• Switch outside HPS lighting to
UCD Lighting
• Reduces energy usage by 70%
• Total of 100 pole lights
Cost = $23,993
Savings = $8,656 / yr
New
Payback = 2.75 yrs
Energy Reduction = 123,662 kwh/yr
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Semiannual Kaizen Blitz
FY12 Water Reduction
800000
Gallons
600000
400000
630,000 gallons saved using
Nano Filtration system to
recover 70% of lost water
655,000
411,000
200000
0
Target
Actual
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Semiannual Kaizen Blitz
6/7 cycles
History
• Average Summer monthly
usage = 1,000,000 gallons
• Average waste = 150,000
gallons
Projected
• 70% of lost water will be
saved with filter
• 105,000 gallons will be
put back in system
1/7 cycles
Nano Filter
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Semiannual Kaizen Blitz
FY12 Waste Reduction
70000
Kilograms
60000
50000
More than $70,000 savings
identified through improved
waste recycling opportunities
62,000
40000
30000
27,000
20000
10000
0
Target
Actual
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Semiannual Kaizen Blitz
Covanta Go-and-See
• Environmental Team Members
visited Covanta site
• Potential Items to be recycled:
– Cardboard
– Plastic
– Paper
– Parts
– Dunnage
• Target 50% of load diverted to
recycle stream
Driver left debris when
leaving compactor
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Summary
• Empower Your Team Members
• What Gets Measured Gets Done
• Never Stop Improving
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Any questions?
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