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  • CSR Social Activities

    Report on Environmental Activities

    Fiscal 2019 Results (2020 Environmental Vision)

    [Boundary of reporting]

  • Toyota Boshoku: Global Mainstay Hub, plants and offices in Japan (17 plants)
  • Japan affiliates: Production entities (9 companies), others (7 companies)
  • The Americas region: Regional Management & Collaboration Hub (1 company), production sites (10 companies)
  • Asia & Oceania region: Regional Management & Collaboration Hub (1 company), production sites (11 companies)
  • China region: Regional Management & Collaboration Hub (1 company), production sites (12 companies)
  • Europe & Africa region: Regional Management & Collaboration Hub (1 company), production sites (8 companies)
  • Establishment of Low Carbon Society

    From the 2020 Environmental Action Plan, the Toyota Boshoku group used production volume instead of sales, which is susceptible to external factors, for the denominator of intensity performance metrics used to manage the action items 1-7 so that improvements are more accurately measured. Likewise, the calculation method for CO2 emissions from logistics (item 8) will be revised in order to measure the improvement more accurately.

    (Assessment : Achieved、x:Not achieved)
    Action item Specific action FY2019 targets FY2019 results Evaluation
    Production 1 Promote the development of innovative production technology with low CO2 emissions
  • Reduce CO2 emissions from new processes by 30%, promote the development of innovative production technology
  • Aim to set CO2 reduction targets through planned integration of mid- to long-term production and development items for CO2 reduction until 2030
  • Target figures were set for CO2 reduction targets through planned integration of mid- to long-term production and development items for CO2 reduction until 2030
  • Downsize processes, reduce transfer distance and reduce the number of cylinders and components as part of efforts to ensure compact design
  • Reduce the amount of energy used through the development of next generation moulding, decoration & assembly methods
  • Promote the reduction of CO2 emissions through the introduction of co-generation equipment
  • Examine introducing co-generation system and increasing efficiency of existing facilities
  • Examined the possibility of introducing a cogeneration system in such locations as the Kariya Plant and Takaoka Plant, and enhanced efficiency at the Sanage Plant and Gifu Plant
  • 2 Promote the use of renewable energy suitable for individual countries and regions
  • Expand the areas to introduce renewable energies, considering the characteristics of inrespective countries and regions (Economic efficiency/Reduction of CO2 emissions)
  • Set target figures for the planned introduction overseas and until 2030
  • Completed setting targets for the planned introduction in the Asia/Oceania region and 2030 targets
  • 3 Study the possibility of utilising next generation energy within the company, and define the mid- to long-term outlook for the utilisation of such energy
  • Study the possibility of utilising next generation energy for processes and motors, and clarify the outlook for the utilisation of such energy
  • Continue examining trends for next-generation energy such as hydrogen and create a mid- to long-term roadmap
  • Completed creation of a mid- to long-term roadmap for next-generation energy
  • 4 Minimise the CO2 emissions in daily production activities
  • Thoroughly eliminate waste in energy use through the pursuit of improved productivity and E-Jit activities*1
  • Devise a mid- to long-term plan until 2030 and share it internally
  • Selected 40 priority items to be carried out globally, with a focus on zero-investment items; devised a mid- to long-term plan until 2030 and shared it internally
  • Reduce CO2 by completing investment zero items*2 decisively, and promote and maintain the activity
  • Actively replace low-efficiency equipment with high-efficiency equipment
  • Promote the understanding and reduction of the energy basic unit for products & processes
  • Look into a framework for implementation and usage method based on a mid- to long-term plan
  • Completed implementation in line with plan and formulated a management system to reduce energy consumption
  • Product 5 Product development that contributes to top-level fuel efficiency
  • Reduced product weight (Seat, interior, filter/power train)
  • Heat management (Reduced air-conditioning load through the development of heat insulation materials)
  • Commercialise door trim using lightweight base material
  • Commercialise ceiling using different mass per unit base materials
  • Commercialise TGV intake manifold
  • Commercialised door trim using lightweight base material
  • Commercialised ceiling using different mass per unit base materials
  • Commercialised TGV intake manifold
  • 6 Promote product development to support next generation automobiles
  • Development of high efficiency technology for filters and power trains => Increase the mass production of HV motor components and FC components
  • Prepare production for HV motor orders
  • Prepare production for FC components
  • Completed preparations for production for HV motors
  • Completed preparations for production for FC components
  • 7 Expand development and commercialisation of products using plant-derived materials
  • Utilisation of plant-derived materials for automotive parts
  • Continue to utilise plant-derived material
  • Commercialised items using kenaf base material
  • Logistics 8 Reduce CO2 emissions through the pursuit of efficient logistics activities
  • Reduce the CO2 emissions through improved transportation efficiency and further improvement of activities with low fuel efficiency
  • Reduce CO2 emissions by enhancing logistics efficiency
    Target: 7,765t-CO2
  • Reduced CO2 emissions with a result of 6,902t-CO2 by:
    1)Enhanced load efficiency
    2)Revised transport routes
    3)Made modal shift
    4)Revised vehicle classifications
    [Targets regarding 1~8]
    Region Base year Unit 2020 targets FY2019 targets FY2019 results Evaluation
    Production
    Toyota Boshoku group
    FY2011
    Basic unit: t-CO2 / 1,000 unit
    Reduce 15%
    42.8
    39.9
     
    Toyota Boshoku
    (non-consolidated)
    FY2009
    Basic unit: t-CO2 / 1,000 unit
    Reduce 17%
    18.2
    16.4
    FY2009
    Emission: t-CO2
    Reduce 17%
    55,958
    51,908*3
    Logistics
    Toyota Boshoku
    (non-consolidated)
    FY2011
    Emission: t-CO2
    Reduce 10%
    7,765
    6,902
  • *1 Energy-Just In Time activities: This refers to using just the required amount of energy at the required time to produce the required amount and activities to eliminate waste when using energy.
  • *2 Item enabling efficient energy conservation simply through modification without the need for investment.
  • *3 Emissions excluding the effects of co-generation in reducing CO2 totaled 57,016t-CO2.
  • CO2 emissions data that has been assured by an independent assurance provider is marked with this ▶
    assurance symbol (click here for details).

    Establishment of Recycling-based Society

    From the 2020 Environmental Action Plan, the Toyota Boshoku group used production volume instead of sales, which is susceptible to external factors, for the denominator of intensity performance metrics used to manage the action items 11 so that improvements are more accurately measured.

    Action item Specific action FY2019 targets FY2019 results Evaluation
    Production 9 Reduce the amount of water used in production activities and wastewater
  • Promote innovative activities including line modification with downsizing
    (Development of processes with minimum water consumption)
  • Continue promoting water usage reduction activities in consideration of the water situation in respective countries and regions
    ・Reduce the water consumption by eliminating waste and increasing efficiency
    ・Reduce the amount of water used by recycling
  • Reuse factory wastewater and rainwater depending on application
  • Change processes with high water consumption and ensure efficient use
  • Ensure thorough daily management by installing a flow meter in every channel
  • Japan: Implemented activities to prevent waste and water leaks by installing water gauges for every process and equipment
  • The Americas: Conserved water by optimising operation of cleaning tower
  • Europe/Africa: Added rainwater tanks to use for irrigation in the green belt
  • Asia/Oceania: Reused wastewater from the dyeing process in processing and further dyeing through the RO system*3
  • China: Installed water gauges to determine water consumption in each process
  • Logistics 10 Reduce the use of fossil fuel resources through the utilisation of plant-derived materials
  • Promote the use of recycled materials & drive further recycling
  • Set target for reducing PP costs for kenaf
  • Completed setting targets for technical challenges to reduce weight of kenaf compounds
  • Promote the development & design enabling effective use of resources through the further utilisation of plant-derived materials
  • Clarify method for reducing CO2 emissions
  • Confirmed effects in reducing CO2 against existing plan to use plant-derived materials
  • Production 11 Reduce the amount of waste generated in production activities and promote the effective use of resources
  • Development of production technology to generate less waste
  • Reduce waste through daily Kaizen activities
    - Promote activities to reduce waste such as by improving yield
    - Promote activities to reduce resource loss (separation/recycling)
  • Promote the production of RSPP effectively utilizing resources (waste)
  • Japan: Recycled offcut waste generated in the kenaf moulding process
  • The Americas: Increased carpet yield and reused pallets
  • Europe/Africa: Made compost from general waste (tea leaves) generated from tea drunk during breaks and lunchtime, etc.
  • Asia/Oceania: Reused hot melt scraps as raw materials
  • China: Made plastic containers from urethane drums and recycled hot melt scraps
  • Logistics 12 Reduce the amount of packaging materials used in logistics activities and effective use of resources
  • Promote the use of returnable containers and lighter-weight packaging materials. Further promote the reduction of packaging materials used
  • Eliminate packing boxes for export products
  • Reduce materials by revising their usage
  • Made returnable packing boxes for export products and eliminated one-way packing materials
  • Made a benchmark for cardboard boxes and reduced weight by switching materials
  • [Targets regarding 11·12]
    Region Base year Unit 2020 targets FY2019 targets FY2019 results Evaluation
    Waste emissions
    Japan Region
    FY2011
    Basic unit: t / 1,000 units
    Reduce 10%
    2.0
    1.7
     
    Toyota Boshoku
    (non-consolidated)
    FY2009
    Basic unit: t / 1,000 units
    Reduce 12%
    1.97
    1.5
    Zero direct landfill waste*5
    Maintain zero direct landfill waste
    Packing and packaging material usage
    Toyota Boshoku
    (non-consolidated)
    FY2009
    Usage: t
    Reduce 12%
    2,301
    2,217
  • *4 A system to purify water using Reverse Osmosis
  • *5 Recycled Sound-Proofing Products: A sound-proofing material for vehicles made from separated and recycled urethane and fibers from vehicle shredder dust
  • *6 Definition of zero direct lanfill waste: Rate of direct landfill waste is less than 1%
  • Establishment of Symbiotic Society

    Action item Specific action FY2019 targets FY2019 results Evaluation
    General 13 Promote the environmental social contribution programmes through forest-creating activities / forest conservation activities
  • Promote strengthening of forest-creating and greening activities through social contribution activities [Tree planting number 170K trees (Cumulative No.: 500K trees)]
  • Promote forestation activities in collaboration with NPOs
  • Promote the awareness-raising activities and education for “forest & nature conservation”
    1. 1. Global tree-planting activities
      a) Conclude agreements with NGOs and implement
      b) Tree-planting: 54,000 trees
    1. 1. Global forest-creating activities
      a) Prepared agreements for NGOs and confirmed sites
      b) Trees planted: 34,060* Cumulative total: 420,281
    x
    1. 2.Promote activities to create forests in Japan
      a) Forest maintenance: 12 times
      b) Tree-planting: 300 trees
    2. 3. All-Toyota Harmony with Nature Working Group
      a) Participate/cooperate with events: 4 times
      b) Prepare and distribute information on group activities
    1. 2. Promoted activities to create forests in Japan
      a) Forest maintenance: 12 times
      b) Trees planted: 1,309
    2. 3.All-Toyota Harmony with Nature Working Group
      a) Participated/cooperated with events: 4 times
      b) Prepared and distributed information on group activities

    Environmental Management

    Action item Specific action FY2019 targets FY2019 results Evaluation
    General 14 Promote the reinforcement of the consolidated environmental management
  • Build the structure to promote 2050 Environmental Vision and develop a scenario/road map to achieve the targets
  • Toward 2050, promote the development of products, materials and methods and clarify the outlook for such development
  • Formulate a mid- to long-term plan to achieve the 2050 Environmental Vision (Set a concrete action plan and reduction targets, etc.)
  • Formulated 2030 scenarios and set targets as mid-term policy to achieve 2050 Environmental Vision
  • Strengthen the environmental burden reduction activities through the enhancement of the activities of the environmental committee
  • Conduct mutual audits and implement best practices across the organisation to prevent abnormalities and complaints*6
  • Completed in line with plan with zero abnormalities and complaints
  • Further promote continuous improvement through the enhanced operations of the environmental management system
  • Systematically upgrade to FY2016 edition of ISO14001
  • Completed shift in line with plan in all business entities
  • 15 Strengthen the chemical substance management system
  • Expand and strengthen the control of chemical substances contained in products
  • Promote the replacement with substances with less environmental burden through the development of alternative technologies
  • Establish a control structure for processed chemicals including raw materials and indirect materials
  • <Zero use of four types of phthalate plasticizers*7>
  • Formulate plan for substitution
  • <Zero use of four types of phthalate plasticizers>
  • Formulated plan to substitute material in seats and interior/exterior materials
  • Completed switch to mass-production items for units
  • 16 Reduce VOC*8 emissions from production activities
  • Promote continuous reduction of VOC emissions through daily improvement activities
  • Reduce the amount of waste chemical substances through the introduction of VOC treatment equipment and the development of processing methods
  • Promote reduction of VOC emissions through daily Kaizen activities
    - Enhance coating efficiency by optimising coating conditions
    - Switch to products containing minimal VOCs and water-based solvents
  • Enhanced coating efficiency by introducing a coating robot
  • Changed to products containing minimal VOCs
  • Switched from organic solvents to water-based solvents
    (Plan to complete proposal for and switch to water-based solvents in the coating process for replacement bumpers in FY2020)
  • Region Base year Unit 2020 targets FY2019 targets FY2019 results Evaluation
    Toyota Boshoku
    (non-consolidated)
    FY2011
    Emission: t
    Reduce 10%
    595
    471
    17 Promote environmental activities in collaboration with business partners (suppliers)
  • Strengthen the cooperation with suppliers to promote environmental activities
  • Promote collaboration to establish a structure to work on climate change, water scarcity, resource recycling and environmental symbiosis
  • Hold lectures and workshops with outside instructors on fire and disaster prevention activities with full member participation as part of safety activities with Sunshine (Toyota Boshoku Association) and conduct assessment based on basic fire and disaster prevention requirements
  • Completed 27 items of high priority related to electrical systems from the 100-item checklist for fire and disaster prevention Currently examining the remaining 73 items at each company
  • 18 Promote the environmental management in product development
  • Establish a target management system of life cycle and promote the environmental burden reduction activities in the development & design phases
  • Continue to realise results in product development for each component field toward 2040 targets
  • Continued to realise results in each component field and completed organisation of challenges
  • 19 Strengthen environmental education to pass the environmental conservation activities on to future generations
  • Organise “Environmental seminars” in collaboration with NPO to spread the activities
  • Conduct environmental seminars in conjunction with region and NPOs
  • Conducted an environmental tour for local residents in collaboration with Toyota City
  • Continue to provide visiting education programmes (Tailored education programmes to meet the demand of local schools)
  • Provide visiting education programmes on the environment (2 schools)
  • Provided visiting environmental education programs (two schools)
    [Topics: Global warming, water, resources, etc.]
  • 20 Enhance communication with stakeholders through active disclosure of environmental information
  • Communicate activity information to all the company members through internal newsletters/briefing sessions
  • Further enhance the provision of environmental information through Toyota Boshoku Report and other means
  • Continuously introduce environmental activities through Toyota Boshoku Report, exhibitions, internal newsletter, etc.
  • Further enhanced environmental information (increased environmental information disclosed on our website by 10%)
  • Held environmental lectures during Environment Month and Energy Conservation Awareness Month and strengthened associated activities
  • Disclose information to the environmental assessment agency proactively and enhance communication activities
  • Disclose information in line with plan
  • Disclosed information in line with plan (CDP, etc.)
  • *7 Abnormalities: In case oil, etc., has leaked into a public waterway at a level that exceeds legal, bylaw and agreement standard values
    Complaints: In case of contact from a local citizen, government, etc., alleging physical damage or psychological effects on account of the company
  • *8 Refers to four types of phthalates restricted by the European REACH Directive (BBP, DEHP, DBP, DIBP)
    Mainly used as plasticizers added to provide elasticity to PVC, rubber, etc.
  • *9 VOC: Volatile Organic Compounds (covers 100 substances designated by Japan's Ministry of the Environment)