Environmental Aspects
Production and Logistics
Production
In FY2004, Toyota achieved its
reduction goals in CO2, completed the fouryear plan to implement measures to prevent
soil and groundwater contamination by oil
leakage, and took comprehensive risk
management steps, including actions to
achieve zero non-compliance and zero
complaints. Furthermore, Toyota created
its Fourth Toyota Environmental Action
Plan, with the goal of becoming No. 1 in
production environment efficiency by
FY2010.
Yasuhito Yamauchi
Production Environment Committee
Chairman
Yasuhito Yamauchi joined Toyota in 1968 and has gained
experience in a wide range of engineering, production engineering
and production areas. He became a Managing Director in 1999,
while also serving as the chairman of the Plant Production
Environmental Subcommittee and the Overseas Production
Environmental Subcommittee. He was appointed a Senior
Managing Director in 2001 and has been the Chairman of the
Production Environment Committee since 2003. In June 2005, he
was appointed President of Aisin Seiki Co., Ltd.
In the areas of production and logistics, Toyota continued to take action in FY2004
focusing on the prevention of global warming, reduction of substances of concern,
reduction of waste, and conservation of resources, including water. Toyota was able
to achieve most of its goals in these areas, through the steady, joint efforts of the
production engineering divisions and plants.
The achievement of these goals by Toyota Motor Corporation (TMC) alone is not
sufficient; group companies subject to consolidation all over the world must take
similar actions. Taking action to ensure legal compliance and completely eliminate
complaints from the surrounding communities is also important. Toyota is committed
to further enhancing its environmental initiatives through the participation of all
employees, based on the powerful leadership of company executives at all of its
business entities worldwide, including TMC.
Organization Chart
(Positions and areas of responsibility as of March 2005)
Production Environment Committee
Chairman:
Senior Managing Director Yasuhito Yamauchi
Established in 1963
Discusses and determines important issues
for environmental preservation in
procurement, production and logistics areas,
and promotes comprehensive environmental
protection measures
Production Environment Technology Subcommittee
Conducts technological development focusing on environmental
measures at the pollution source of production equipment and plans
measures for equipment
Overseas Production Environmental Subcommittee
Promotes transfer of environmental preservation technology to
overseas businesses
Plant Production Environmental Subcommittee
Conducts environmental preservation at all plants
and housing works
Environmental Manager by Region
(Plant General Manager)
Environmental Preservation Secretariat by Plant
Production Environment Logistics Subcommittee
Promotes reductions in environmental impact caused by logistics
30
Volume of Resources Input and
Volume of Substances Released
In the production area, Toyota uses
many types of resources and energy, and
releases such things as CO2 and waste.
The logistics area also releases CO2 during
the course of transporting completed
vehicles and parts.
The figure on the top of the next page
shows the volumes of resources and
energy input and the volume of substances
released in FY2004 in production and
logistics processes.
A total of 1.67 million tons of raw
materials and supplementary materials,
34.5 x 106GJ of energy in the form of
electricity and fuel, etc., and 14.3 million
cubic meters of water, were used at Toyota.
1.54 million tons-CO2 of greenhouse gases
and 11.84 million cubic meters of water
were released into the atmosphere and
waterways respectively. Of 546,000 tons of
the total volume of waste generated and
not processed by Toyota, 540,000 tons was
reused as recyclable resources in the form
of raw material for steel, and 6,000 tons
was disposed of in landfills.
In logistics, CO2 emissions during the
transport of 3.5 billion ton-kilometers of
completely built units and parts amounted
to 285,000 tons-CO2.
Production Environment
Management
FY2004 Goals
• Promotion of measures to prevent soil
and groundwater contamination
• Expansion of best practices to prevent
abnormalities1 and complaints that
occurred at other plants
Plant EMS Internal Audits
In FY2004, Toyota conducted internal
audits at eight of its plants and housing
works, and the results satisfied ISO 14001
requirements. On-site follow-up audits
conducted three to six months later verified
Environmental & Social Report 2005
Volume of Resources Input and Volume of Substances Released into the Environment from 10 Production Plants and Logistics in FY2004
Gases emitted
into the atmosphere
Input
Volume of greenhouse gases2 emitted
(1,538.7 thousand tons-CO2)
CO2: 1,535.5 thousand tons
Gases other than CO2: 3,200 tons
Volume of substances subject to PRTR
(3,000 tons)
CO2 emissions
(285,000 tons-CO2)
Gases emitted
into the atmosphere
Production Process
Press
Painting
Welding
Engines
Casting and
Forging
Machine
Processing
Transmissions,
etc.
1. GJ (giga joule) = 10 J
2. 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
Input
Assembly
9
Thermal
recovery
Volume recovered as thermal
energy by Toyota (8,600 tons)
1. Abnormalities:
Legal non-compliance, accidents and
“near-miss” accidents
Production Engineering EMS
Internal Audits
Toyota conducted internal audits at its
nine divisions related to production
engineering responsible for facility planning,
focusing on the status of (1) legal compliance
(notice to authorities), (2) prevention
(environmentally conscious designs), and
(3) environmental performance improvement
(production process improvements), all of
which are goals of the Production
Total transportation volume in Japan
(3.5 billion ton-kilometers)
Volume of wrapping and packaging
materials (49,400 tons)
Volume of waste generated
and not processed by Toyota
Total volume of waste generated (546,000 tons)
Volume reused (540,000 tons)
Final volume disposed of (6,000 tons)3
Volume of substances subject to PRTR (300 tons)
Released into waterways
Total amount of wastewater
(11.84 million m3)
Volume of substances subject to PRTR
(14 tons)
that all of the improvement requirements
identified by the main audits had been
satisfied.
In FY2005, in an effort to not only
satisfy but go beyond the ISO requirements,
Toyota is switching to an auditing method
that determines whether the PDCA cycle is
effectively functioning in three key areas:
(1) Legal compliance (zero abnormalities
and complaints), (2) Prevention (risk
minimization), and (3) Environmental
performance improvement (No. 1 in the
world, No. 1 in each region). The new
audits will also continue to include as
important auditing items “addressing
issues raised in the past at each plant,”
“comprehensive daily management of
facilities to prevent soil and groundwater
contamination,” and “propagation of the
best practices of other plants to prevent
abnormalities and complaints.”
Environmental
Aspects
Logistics
Total materials volume input
(1.67 million tons)
Amount of materials reused in automobile
production processes of Toyota (390,000 tons)
Total energy consumption (34.5 x 106GJ)1
Renewable energy consumption
(Wind power generation: 258GJ)
Water consumption (14.3 million m3)
Volume of substances subject to
PRTR (17,000 tons)
Volume of substances subject to PRTR
disposed of at landfills within business sites (5 tons)
Engineering EMS. Follow-up audits verified
that all of the improvement requirements
identified by the main audits had been
satisfied. In FY2005, Toyota plans to
conduct audits to assess how firmly the
improved systems have been established,
with a particular focus on legal compliance
and the elimination of environmental
accidents.
Collaboration between Plant EMS and
Production Engineering EMS
Plant EMS
Zero
abnormalities
and complaints
Risk minimization
No. 1
in the world,
No. 1 in
each region
Three Key Areas of Production Environment
Legal compliance
Notice to
authorities
Prevention
Environmentally
conscious
designs
Environmental
performance
improvements
Production
process
improvements
Production Engineering EMS
Legal Compliance Activities
Achieving Zero Abnormalities and
Complaints
In this area, Toyota continued to expand
implementation of best practices to prevent
11 kinds of potential complaints and 77
actual cases of abnormalities, complaints
or “near-miss” accidents2 identified during
a four-year period (1999 - 2002).
Examples of “near-miss” accidents
included oil release into storm drains from
oil-contaminated pallets left outdoors, oil
leakage onto intra-facility roads from poorly
maintained vehicles, and noise from
loading operations. By the end of March
2005, use of the best practices was
expanded to all departments that could
benefit from the shared information.
2. Near-miss accidents:
Potentially high-risk incidents that did not
lead to actual accidents
Identification of New Issues and
Respective Responses
When Toyota established clear internal
standards for infrequent and non-constant
noise and reevaluated the situation, it
identified eight cases of concern, including
parts-loading noise at the engine-shipping
docks. Toyota will take the necessary
measures to rectify the situation by the end
of FY2005.
Similarly, Toyota intends to examine
enhancing its in-house offensive odors
standards.
31
Environmental Aspects
Production and Logistics
Integrating Power Supply and
Maintenance Allows Centralized
Monitoring
The Power Supply and Maintenance
Center located at the Motomachi Plant
(Toyota City) not only manages power for 12
plants, but also manages activities to prevent
abnormalities and complaints through the
use of monitoring cameras and special sound
detection microphones. Several cameras
are installed at wastewater treatment
facilities, chemical storage locations and
smokestacks, which have a high potential
for environmental contamination, allowing
monitoring of these sites on video displays.
In some locations where plants are close
to residential areas, microphones are
installed, and if a noise level exceeding the
standard is detected, the operation in
question is immediately stopped.
Central management of operations status at 12 plants
Preventive Measures
Reporting and Storing Devices
Containing PCB
In FY2004, Toyota reported to the
government on its storage of the same
number of transformers and condensers
(5,247) that contain PCB (polychlorinated
biphenyl) as in FY2002. Toyota continues
to safely store these devices in accordance
with the standards specified by law to
prevent leakage and soil contamination.
Soil and Groundwater-related Measures
Toyota completed the soil remediation
measures in FY2001 that it had been
carrying out at six plants. In terms of
groundwater contamination prevention,
Toyota completed an effluent-prevention
measure in 1997 which involved the digging
of barrier-type wells and has continued
groundwater remediation using pump and
treat technology. Toyota reports levels of
trichloroethylene to the government, as
well as to local councils in the surrounding
communities.
32
Trichloroethylene Measurement Values
in FY2004 Environmental standard: 0.03 Unit mg/l
Plant
Levels in groundwater
Honsha
Less than 0.002 - 1.570
Motomachi
Less than 0.002 - 1.080
Kamigo
Less than 0.002 - 0.462
Takaoka
Less than 0.002 - 0.748
Miyoshi
Less than 0.002 - 0.454
Tsutsumi
Less than 0.002 - 0.926
*Measurements are taken at all plants and housing business sites
*Has not been detected in plants other than those listed (at the
three housing business sites, measurements began in 1997)
*The level has a range since each plant includes multiple
measurement points
Prevention of Soil and Groundwater
Contamination by Oil Leakage
Toyota implemented actions to prevent
soil and groundwater contamination by oil
leakage in accordance with a four-year plan
that began in 2001. Toyota has adopted all
of the actions of the plan, including dualwalled structures for underground pits,
storage tanks and oil grooves as well as
facilities for monitoring on a daily basis. In
the future, prevention through daily
monitoring will be strengthened. Toyota
plans to firmly establish the practice of daily
monitoring by checking its implementation
status through Plant EMS audits.
Actions to Prevent Soil and Groundwater
Contamination
Physical measures
Visibility measures
• Relocation to above
ground
• Dual-walled structure
• Double-layer structure
• Fluid level monitoring
• Alarms
Future actions
Implementation of
daily monitoring
EMS internal audits
Communication with Surrounding
Communities
Each of Toyota’s plants and housing
works holds a community council meeting
once a year to communicate Toyota’s
environmental initiatives and engage in
dialog with people in the surrounding
communities. In FY2004, all plants and
housing works held their community council
meetings between October and December.
At these meetings, Toyota explained its
methods for managing chemical substances,
reported on environmental conditions around
the plants, and exchanged relevant opinions.
Some local community members
expressed their concern about hazardous
substances in the event of an earthquake.
Prevention of
Global Warming
FY2004 Goal
Reduce total CO2 emissions volume per
year to 1.57 million tons or less
Toyota had established a goal of
keeping the combined total CO2 emissions
from its 10 plants to 1.57 million tons or
less. Through the dedicated efforts made
jointly by all of the plants, the actual
emission was 1.54 million tons, enabling
Toyota to meet the goal.
Beginning in FY2005, Toyota plans to
expand its goal to cover offices, research
facilities, etc. in addition to plants, and
promote energy conservation in these
facilities as well.
CO2 Reduction by Increased Efficiency
and Streamlining of Power Supply
Infrastructures
To further improve its power efficiency
and streamline its power supply
infrastructures, Toyota believes it is
important to (1) Increase energy conversion
rates and reduce supply loss, and (2)
Computerize the operation and inspection
of power facilities. In order to achieve
these goals, Toyota has been taking
comprehensive steps.
First, Toyota worked on computerization
and reducing energy supply loss. Until
recently, the running of power supply
facilities used to depend on operators’
intuition and expertise gained from years of
experience.
However, because these
operators focused too much on actions to
handle sudden problems or abrupt load
fluctuations, they tended to operate
facilities at unnecessarily high levels.
Additionally, because a wide variety of
standards had been established to support
the different operating modes of individual
plants, effective overall operation was
difficult.
To resolve these issues, Toyota decided
to carry out planned, efficient operations
by setting a common operation standard
and making energy load forecasts for the
following day based on local weather
forecast data and production plans.
Toward this goal, Toyota developed the
Power Supply Optimization System, which
acts as the actual brain for controlling
operations, and also took various
measures such as introduction of the latest
high-efficiency boilers and switching the
fuel used from heavy oil to natural gas.
Environmental & Social Report 2005
Company-wide Calorific Energy Use Ratio
Company-wide CO2 Emissions (Energy Consumption) and CO2 Emissions per Sales Unit
(including non-production areas)
Kerosene 0.3%
Natural gas
16.4%
Electricity
61.8%
(Tons/Billion Yen)
Total CO2 emissions from production areas (energy consumption)
2.4
CO2 emissions per sales unit
2.2
2,0
400
2.12
0.13
1.99
1.93
0.17
1.8
291
1.76
1.6
1.85
1.84
0.17
0.17
1.68
1.67
1.80
1.78
0.18
0.19
1.62
244
224
1.4
300
1.59
200
210
200
194
’02
’03
’04
0
’90
’00
’01
0
Environmental
Aspects
A-type
heavy oil
16.1%
Total CO2 emissions from non-production areas (energy consumption)
CO2 emissions per sales unit
Butane gas
3.5%
Coal 0.8%
Total CO2 emissions (energy consumption)
(Million Tons)
Coke 1.1%
(FY)
Note 1: Data for housing works as well as that for non-production areas such as offices were added to the previously reported figure for
the automobile production process
Note 2: For facilities in non-production areas for which FY1990 or FY2000 emissions data is not available, the oldest subsequent data
available is used for the graph
Please see p. 82 for the CO2 conversion coefficient
Purchase of Green Power
Toyota concluded a Green Power
Certification System agreement with Japan
Natural Energy Company Limited. Based
on this subcontracting agreement Toyota
once again used two million kWh of windgenerated power in FY2004.
Optimization of Air-conditioner Operation Control
Toyota set the long-term goal of
reducing CO2 emissions per airconditioner (kg CO2/unit) by half from
the FY1995 level by FY2007. The two
key premises for this are: (1) Reduction
of energy requirements by establishing a
technology to achieve optimum operation
based on load forecast, and (2) Reduction
of energy requirements at each plant by
reevaluating the standards used for
operation, control, management, and
maintenance.
First, Toyota optimized the operation
standards, which used to rely on the
intuition of operators. Then, Toyota
evaluated various standards that could
lead to the greatest energy savings, and
created optimum standards through
repeated trials and data analysis.
Toyota also made many other meticulous
improvements in areas such as the
operation of secondary water supply
pumps and the method of controlling the
cooling water temperature, and as a
result, successfully reduced CO2
emissions by 2,618 tons from the
FY1995 level (by 44% in kg CO2/unit).
Many Energy-conserving Designs Incorporated
into the New Head Office Building
Many techniques for reducing
environmental impact were incorporated
throughout the New Head Office Building,
which was completed in February 2005.
From the design stage, Toyota adopted 73
of the 110 environmentally sound methods
designated by the Ministry of Land
Infrastructure and Transport. Some of the
major steps taken include load reduction,
utilization of natural energy, effective use
of energy, and use of ecological materials.
For example, to reduce the load borne
by window surfaces, the new building
uses canopies to shut out the sunlight, as
well as air barriers, low-e glass, and
automatic control of blinds, substantially
reducing the volume of CO2 emissions
compared to conventional glass windows.
Many other environmentally conscious
steps have also been taken, including
reduction of electricity requirements for
lighting through the use of optical duct
systems, use of floor-flow air conditioning
systems, and natural ventilation utilizing
the chimney effect, resulting in expected
CO2 reductions of 40% over the entire
lifecycle of the building compared to
conventional buildings.
Lighting using an optical ducts system for
the employee cafeteria
As a result, the new building achieved
the Class S (the highest) ranking according
to CASBEE,* which assesses the
environmental quality and impact of
buildings.
*CASBEE: Comprehensive Assessment System for Building Environmental Efficiency
33
Production and Logistics
Trend in Discharge Volumes of Substances
Subject to PRTR at Production Plants
Reducing Substances of
Concern
(Tons)
6,000
5,100
5,000
• Body painting process: Reduce VOC
emissions to an average of 37g/m2 or
less for all lines
• Reduce yearly discharge volumes of
toluene and xylene (substances subject
to PRTR) to 2,500 tons or less
Reducing VOC Emissions
In FY2004, Toyota continued to promote
the introduction of water-borne paints as a
measure to reduce volatile organic
compounds (VOC) emissions. Conversion
to water-borne paints for the top coating
(base coat) was completed at nearly all of
the lines. Toyota also took additional
actions, such as reducing paint solvent
usage and increasing the recovery rate
after use, and as a result, surpassed the
goal for FY2004 (an average of 37g/m2 for
all lines) by achieving 35g/m2.
Trend in VOC Emissions Volume in Automobile
Painting Process (Average of All Lines)
(g/m2)
Emissions volume
60
55
51
50
44
41
40
0
35
’00
’01
’02
’03
’04 (FY)
Reducing the Volume of Substances
Subject to PRTR
Of the substances subject to PRTR,1
toluene, xylene, ethylbenzene, and 1,3,5trimethylbenzene are found in Toyota’s
production processes and account for 97%
of the total volume. Toyota has been taking
various steps to reduce the usage of
substances subject to PRTR, including
introducing water-borne paints, reducing
purge solvent usage, and increasing
recovery rates.
As a result, the actual released volume
of substances subject to PRTR was 3,000
tons in FY2004, which surpassed the
original FY2005 goal (3,140 tons) one year
early but fell short of the revised FY2004
goal (2,500 tons).
In FY2005, Toyota is expanding the
targets of reduction actions to include
bodies, bumpers, and instrument panels,
etc., and is determined to achieve the goal
of only 2,000 tons for the year.
1. PRTR:
Pollutant Release and Transfer Register
Please see p. 85 for details on PRTR
34
Discharge volume
FY2004 Goals
3,900
4,000
3,600
3,500
3,000
3,000
2,000
1,000
0
’00
’01
’02
’03
’04
(FY)
Recipient of the 2004 PRTR Awards
Excellence Prize
Toyota received the Excellence Prize in
the 2004 PRTR Awards run by the Center for
Environmental Information Science (CEIS).
The contest is designed to encourage
businesses to assess by themselves the
environmental impact related to the release
of chemical substances, promote sound
management, and obtain the understanding
of the general public.
The Excellence Prize Toyota received
in 2004 is given to business entities
(corporations) that are proactively taking
steps to manage chemical substances
and communicate their risks. CEIS’ reason
for giving the award to Toyota was as
follows: “Toyota not only systematized its
chemical substance management, but also
established the Eco-Research Corporation2
to commercialize PRTR data collection work
based on its own know-how, and has been
actively helping other businesses that lack
the necessary know-how. For these actions,
Toyota should be highly commended.”
2. Eco-Research Corporation:
A company that was established jointly by
Toyota and Hitachi Group in March 2001
and helps other companies comply with
the PRTR Law
Initiatives to Conserve Resources
FY2004 Goals
• Reduce usage of primary raw materials
by 11,000 tons or more
• Limit usage of foundry sand to 21,500
tons or less
• Limit usage of oils and fats to 11,100kl
or less
As for primary raw materials,3 Toyota
implemented various measures to reduce
resource loss, such as improving the yield
in each production process, reducing the
number of defective pieces, reducing the
number of parts required, and reducing the
required machining by integrating parts or
redesigning parts shapes.
Toyota also took steps to reduce its
usage of foundry sand by, for example,
expanding and consolidating the production
of aluminum engine blocks.
With regard to reducing the usage of
oils and fats, Toyota implemented various
routine measures such as eliminating where
possible the need for oils in the first place
by consolidating lines, preventing leakage
through early detection and maintenance,
and switching to reusable oils and fats.
As a result, Toyota reduced its primary
raw materials usage by 17,330 tons and
used 11,100kl of oils and fats, thus
achieving its FY2004 goals. However, the
usage of foundry sand was 23,200 tons,
which was 5,700 tons less than in FY2003
but fell short of the FY2004 goal.
3. Primary raw materials: iron, aluminum, etc.
Changes in Reclamation Rate
(%)
100
Reclamation rate
Environmental Aspects
95
90
85
80
0
’90
’00
’01
’02
’03
’04 (FY)
External recycling volume
Reclamation
=
rate
Volume of waste not processed by Toyota
=
Amount of recycling for a fee* +
amount of recycling for free/
amount of money back recycling
Volume of waste generated +
amount of recycling for free/
amount of money back recycling
100
100
*Money back recycling is a case where the seller obtains a profit
after accounting for transport and handling costs. Therefore,
a case where no profit or payment is made after accounting for
transport and handling costs is called recycling for free and a
case where a payment must be made to the recycling business
is called recycling for a fee.
Reducing the Volume of Waste Generated
FY2004 Goal
• Reduce the volume of waste generated
(excluding that recycled) to 12,000 tons
or less (an 80% reduction from 1990)
After achieving zero landfill waste4 from
production plants in December 2000,
Toyota achieved the same goal at its nonproduction bases in December 2003. The
volume of landfill waste generated from
both production plants and non-production
bases in FY2004 was less than 1% of the
FY1995 level, and the goal of zero landfill
waste was met once again.
Toyota
significantly reduced the volume of waste
generated in FY2004, including the portion
that was recycled, through reduction
measures at the source, such as reduction
in the volume of industrial dust collected
from casting processes and selling off
scrap from grinding processes.
Excluding the amount that was recycled,
the volume of waste generated was 10,482
tons/year, achieving the FY2004 goal.
4. Zero landfill waste:
A reduction in landfill waste generated directly
by plants to less than 5% of the 1995 level
Environmental & Social Report 2005
Breakdown of the Volume of Waste
Generated in FY2004
(Excluding that Recycled)
Overview of Waste Disposal (FY2004 Results)
(Unit: Thousand Tons/Year)
Coal: 11.4
RDF*: 12.9
(Excluding that recycled)
10,482 tons
Incinerated at
Environment Center
10.5
Combustible
Paintrelated
33%
8.4
Amount reduced
(Thermal recovery)
0.9
0.9
Hazardous dry
cell batteries,
hazardous dust, etc.
Intermediary
Incombustible processing by outside
0.03
subcontractor
Plastic
waste
21%
Subcontractor
2.1
Volume of waste generated
143
Amount of
recycling for a fee
Volume of
combustible waste
Volume of
landfill waste
Volume of
waste
generated
120
80
81
86
79
66
31
22
0
80
69
40
18.2
13.5
10.5
’03
’04
1
’90
’00
’01
Externally-controlled landfills
4.9
’02
(FY)
Reduction of CO2 Emissions Associated
with Waste Disposal
As part of Toyota’s efforts to promote
recycling, in order to reduce the CO2
emissions associated with waste disposal,
Toyota compared the volume of CO2
emitted from in-house inceneration with
that from external recycling for each waste
item, determining which method emitted
the least CO2 for each item. As a result,
Toyota was able to reduce the CO2
emissions associated with waste disposal
in FY2004 by approximately 1,000
tons/year from the FY2003 level. In the
future, rather than simply promoting the
elimination of combustible waste, Toyota
plans to pursue waste disposal methods
with the least environmental impact.
To handle combustible waste, Toyota
has been utilizing fluidized bed boilers*
and cogeneration systems, and was able to
efficiently recover approximately 9,000kl/year
of energy (in oil equivalent) in FY2004.
*Fluidized bed boiler:
Sand that is heated to high temperature is
turned into a fluid state and swirled by
injecting air through the boiler bed, and waste
is then fed into the center.
The boiler recovers the energy generated by
the combustion of the waste and uses this
energy to generate steam.
Please see p. 85 for details on
cogeneration systems
Water Consumption/Air and Water Quality Data
Water consumption remained basically
the same as the previous year.
In data accumulated by Toyota on air
quality, emissions of SOx (sulfur oxides)
continued to decrease. NOx (nitrogen
oxide) emissions have been declining
slightly because of a fuel switch from
butane to natural gas. With regard to water
quality data, nitrogen, phosphorus and
COD whose aggregate levels in waterways
are regulated, all continue to be at levels
that are only 10 to 50% of those allowed by
regulations.
Trend in Water Consumption per Vehicle
in Automobile Assembly Plants
(m3/Vehicle)
6
Groundwater
Tap
water
Industrial
water
16
2.2
14
12
14.2
2.2
13.1
2.1
1.9
2.0
11.6
11.9
12.9
10
8
6
5.0
4.1
4.0
’03
’04
3
2
1
0
’00
’01
’02
(FY)
Trends in Volumes of Nitrogen and
Phosphorus Emissions Included in
Wastewater
3
18
5.4
4
Trend in Total Water Consumption at
Vehicle Production Plants
(Million m )
20
5.4
5
(Tons)
100
Yearly emissions volumes
160
Nitrogen
Phosphorus
95
83
83
80
71
59
60
40
4
2
0.2
0
’00
0.7
0.9
’01
’02
0.4
0.5
’03
’04
20
10
(FY)
0
Trends in Emissions Volumes of Nitrogen
Oxides and Sulfur Oxides
NOx
(Thousand m3 N)
500
NOx and SOx emissions volumes
160
Isolated landfills
0.002
Note: The details of non-combustible waste are not included because they are minuscule
*RDF (Refuse Derived Fuel): Solid fuel derived from waste
Volume of Waste Generated
(Thousand Tons/Year)
Harmless casting
waste, etc.
423
426
SOx
448
300
184
174
157
148
6.3
6.9
6.1
6.8
’00
’01
’02
’03
’04 (FY)
Trend in Volume of COD Included in
Wastewater
472
494
400
200
7.4
(Tons)
120
139
COD emissions volume
Wastewater
sludge
11%
Toyota controlled
landfills
Ash from incinerator 5.8
Environmental
Aspects
Paper
waste
11%
Volume of
Waste Generated
Volume of waste
generated
Waste oil
7%
(Excluding that recycled)
Other
17%
(Energy recovery through
electricity generation)
Fuel
110
107
104
100
96
89
90
86
100
0
’00
’01
’02
’03
’04 (FY)
80
0
’00
’01
’02
’03
’04 (FY)
35
Environmental Aspects
Production and Logistics
Vehicle Logistics Flow
Logistics
Ranges covered
Within Japan
Current
The area of logistics involves transporting
completed vehicles and vehicle parts
throughout Japan and overseas. In FY2004,
Toyota’s transport volume in Japan was
approximately 3.5 billion ton-kilometers
(tonnage times kilometers). Toyota
promoted initiatives to achieve the action
goals established by the Production
Environment Logistics Subcommittee and
proceeded with improvement activities.
Customer
Directly-shipped
products
Completed
vehicle
Procurement
logistics
Production
parts logistics
Completed
vehicle
In-house
production plant
Parts
distributor
in Japan
Overseas
distributor
Parts
center
Service parts
Production
parts
Logistics
center
(Packaging plant)
Plant
Imported parts
Results of CO2 Reduction Actions
Logistics
for
completed
vehicles
Logistics
for
production
parts
Logistics
for
production
parts
Logistics
for
completed
vehicles
Logistics
for
production
parts
Reduction of total transportation distance
Logistics
for
production
parts
Topic
Shift to a mode of transport with
low CO2 emissions per unit
Group
Details
Reduction in CO2
Shift to
marine transport
Switched the transport of engines to Kyushu from
land to marine transport
2,400 tons/year
Improvements in
fuel efficiency
Further promoted Eco Driving
3,700 tons/year
Use of
railway transport
Expanded the use of railway transport for returning
empty containers
Improvements in
loading rate
Improved loading rate using newly designed jigs
and platforms
Improvements in
packing rate
Improved packing rate by loading multiple part
types on the same pallet
Improvements in
loading rate
Improved loading rate through deregulation of trailer
height limits
2,000 tons/year
Shared shipping
Reduced number of voyages by sharing ship space
with other companies
3,400 tons/year
Improvements in
loading rate
Improved shipment packages for loading, etc.
Other
Use of Railway for Production Parts
Transportation on a Trial Basis
200 tons/year
1,000 tons/year
400 tons/year
700 tons/year
15,200 tons/year
Total
29,000 tons/year
Please see p. 82 for CO2 conversion coefficients
Since April 2005, in cooperation with Japan Freight Railway
Company, Nippon Express Co., Ltd., and Toyota Transportation,
Toyota has been using railway shipment, which results in less
CO2 emissions than trucks, on a trial basis. In this trial usage,
parts are shipped in 31-ft railway containers, utilizing the terminal
stations closest to the parts centers in the Toyota district and a
distant plant (Iwate Plant of Kanto Auto Works, Ltd.).
36
Docking port
Procurement
logistics
Logistics
center
Best Practice 1
Supplier
Completed
vehicle
Supplier
• Reduce CO2 emissions to 268,000 tons
or less (reduce CO2 emissions by 14,300
tons or more)
Promotion of Modal Shift
Toyota has been promoting a modal
shift to marine transport and railway
transport, which emit less CO2 per unit of
operation. In FY2004, Toyota switched the
shipment of engines bound for Kyushu to
marine transport and also switched the
shipment of empty shipping cargo containers
from Kanto district to railway transport. In
addition to these conventional approaches,
Toyota also began using railways to ship
production parts on a trial basis in order to
expand the use of railway transport.
Customer
(assembly unit)
FY2004 Goal
In the area of logistics, Toyota’s
initiatives to reduce total CO2 emissions
during the transport of completed vehicles
and parts include improving loading rates,
sharing ship space with other companies
to increase shipping efficiency, shifting to
more efficient modes of transport, achieving
a modal shift, and increasing fuel efficiency.
As a result, CO2 emissions decreased by
29,000 tons in FY2004, achieving the
reduction goal. However, an increase in the
volume of production and a shift of production
sites to distant locations (Kyushu and Tohoku
districts) increased the total transportation
volume and distance, resulting in a total
CO2 emission volume of 285,000 tons.
Overseas
Japanese
dealer
Body
manufacturer
Shipping port
CO2 Emissions Reduction Activities
in Japan and their Results
Promote enhancement of
the management system
Toyota’s Modal Shift Framework
Parts plants in
Toyota district
NishiHamamatsu
Station
Morioka
Cargo Terminal
Station
Iwate Plant of
Kanto Auto
Works, Ltd.
The use of railway transportation is expected to reduce CO2
emissions by approximately 1,000 tons/year compared to truck
transportation and by approximately 200 tons/year compared to
marine transportation.
Environmental & Social Report 2005
Reducing Packaging and
Wrapping Materials
FY2004 Goal
• Reduce usage to 47,000 tons or less
(reduce usage by 1,500 tons or more)
To reduce the volume of packaging and
wrapping materials, Toyota took actions
such as reducing the material volume at
the source, through cooperation between
the logistics and design departments, and
implementing pinpoint wrapping, which
involves wrapping only those areas of
parts that require protection to preserve
their quality. As a result, Toyota achieved
its reduction goal of 2,500 tons. However,
the increase in logistics operations resulted
in a total volume of 49,400 tons.
Environmental
Aspects
Toward Global Expansion
With the implementation of the Kyoto Protocol
in February 2005, the necessity for cooperation
between companies and their shipping service
providers in reducing CO2 emissions is
increasing. An example of such cooperation in
Japan is the Green Logistics Partnership
Conference in the transport sector. Toyota’s
Logistics Division has been reducing CO2
emissions at an annual rate of 19,000 tons over
the last three years (7% a year*). Based on
these results, we plan to set an even higher goal
in Japan and take innovative actions to achieve it.
Additionally, we need to strengthen our initiatives
from a global perspective and incorporate
Toyota’s best practices from Japan at overseas
sites. Toyota is committed to continuing to take
the necessary actions and remaining the leader
in logistics-related environmental initiatives as
well, both in Japan and overseas.
Takeshi Uchiyamada
Chairman of Production Environment
Logistics Subcommittee
Executive Vice President since June 2005
*CO2 reduction rate:
Calculated according to logistics volume based upon the production and sales plan
In this improvement example,
the logistics department participated
at the packaging-shape planning
stage, which led to modifying the
package to a shape that is easier
to transport. Toyota changed the
delivery format for air conditioner
condensers, which used to be
delivered with six attachment hooks.
These attachment hooks have now
been removed, resulting in a switch
to the delivery format of individual
packaging boxes of reduced height.
This improvement resulted in a
10% (0.6 tons/year) reduction in
packaging material usage.
Delivery format with
attachment hooks
Attachment hooks
are stored in the gaps
and the cushioning
material thickness
has been reduced
Results of Reducing Packaging and Wrapping Materials
Group
Topic
Logistics for
production parts
Improved Packaging Boxes for
Air-conditioner Condensers
Increasing the use of
returnable containers
Logistics for
service parts
Best Practice 2
Increasing the use of
returnable containers
Streamlining
Details
Reduction
• Expanded use of returnable plastic boxes
500 tons/year
• Change of packaging specifications
• Conversion of individual packaging boxes for bumpers
to returnable types
• Size reduction in packaging boxes for navigation and
audio systems
2,000 tons/year
Total
2,500 tons/year
Enhanced Environmental
Management
Global Developments
In addition to continuing its supervisory
actions in Japan, in FY2004 Toyota began
assessing actual monthly emissions from
logistics operations for both completed
vehicles and service parts in North America,
and for production parts, completed
vehicles, and service parts in Europe.
In the future, Toyota plans to expand
the regions involved, and advance its goalbased management activities.
Change in the Calculation Method for
CO2 Emissions
In order to correctly evaluate the results
of these actions and calculate CO2
emissions volume, Toyota is reassessing
the calculation method being used. Toyota
is currently using the ton-kilometer method,
which calculates CO2 emissions volume by
multiplying the load volume by the distance
driven and a CO2 conversion coefficient.
By switching from this method to the fuel
method, which calculates CO2 emissions
based on the actual volume of fuel
consumed, by the end of FY2005 Toyota
plans to more accurately assess its CO2
emissions volume and promote further
reduction.
Activities at Logistics Centers
(Zero Complaints from Local Communities)
Toyota employees at the Kamigo
Logistics Center, Inazawa Parts Center,
Oguchi Parts Center, Tobishima Logistics
Center, and Nagoya Wharf Center are all
proactively taking the necessary preventive
measures in terms of preserving water
quality and limiting noise. Each site
continually checks for oil leaks at truck
parking lots to prevent oil leakage,
monitors wastewater quality, and measures
noise levels in the surrounding areas. As a
result, in FY2004, there were no problems
or complaints at any of the sites.
37