TOYODA GOSEI

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Building Recycling Societies

We use resources effectively through product design that reduces waste and water usage and makes recycling easier, contributing to a recycling society.

Reduction of waste

Development of product recycling technology

We develop and engineer products and materials that are easily recyclable and develop waste recycling technologies with consideration of the entire lifecycle of automobiles. We have established recycling techniques for products that previously used several kinds of rubber and products that combined rubber and other materials. These recycling efforts were continued in FY2016 for effective use of resources.

■Development of technology for end-of-life vehicle parts recycling

Key items Measures implemented
New recycling
  • Composite material separation technology
  • New recycling technology
    (high quality material recycling)
Use of recycled materials in vehicles
  • End-of-life vehicle recycling technology
  • Development of applications for recycled materials
Product design for easy recycling
  • Product design for easy dismantling
  • Materials and composition changes for easy recycling
Reduction in waste during production

To reduce waste in production processes, we have been taking measures to combat waste at its source and recycle. In FY2016, reduction activities were conducted based on genchi-genbutsu at each plant and item identification by outside experts. The result was less rubber, plastic and liquid waste. Efforts for liquid waste led to a reduction of 5.8% in total discharge. Study sessions were also held to promote waste reduction at both domestic and overseas Group companies.

Percent decrease in discarded materials volume per sales unit
FY2016 (Compared against FY2012)

  • Japan, consolidated7%decrease
  • Toyoda Gosei Co., Ltd.*17%increase
  • Overseas affiliates (compared with FY2013)40%decrease
  • *1 We have set individual targets for each year to achieve the FY2020 targets, but we did not reach the target for FY2016. In FY2017 we are trying to achieve further reductions tracking fluctuations in sales.
■Waste volume, waste volume per sales unit (index)*2

Japan, consolidated

Japan, consolidated

Toyoda Gosei Co., Ltd.

Toyoda Gosei Co., Ltd.

Overseas affiliates

Overseas affiliates
  • *2 Waste volume per sales unit (index) is a figure obtained
    taking FY2012 as 100

■Amounts of waste generated and disposed of
(results for FY2016: Toyoda Gosei)

Amounts of waste generated and disposed of (results for FY2016: Toyoda Gosei)
Example of waste reduction

Stabilization of mixed compound (rubber) physical properties

Defects reduced 50%

Solid material defects were decreased 50% by stabilizing the physical properties of the rubber compounds used in extrusion parts. These compounds are mixed with added chemicals so that they must be used within a certain time. Changes to the physical properties before the use-by date can be inhibited by maintaining a constant room temperature (~20°C) where compounds are stored. We have reduced defects through measures such as increasing compound storage areas, using air conditioning, and installing fans to circulate the air in production processes so that materials can be supplied to downstream processes while maintaining the same temperature.

Training die maintenance personnel at international locations

Product defects reduced 20%

The product defect rate was decreased 20% by improving the skills of die maintenance personnel. A skill survey of die maintenance personnel at international locations in 2012 revealed inconsistencies between individuals. We opened a dedicated training area in the Nishimizoguchi Plant in 2014 with the aim of developing in-house instructors for various locations. A three-month curriculum was created for the stepwise acquisition of skills. By February 2017, 24 people from 18 overseas locations and three people from two domestic locations had completed this training. Regular maintenance and high-level in-house repair has contributed to prevention of trouble during forming caused by die defects, and to maintaining stable product quality.

Training die maintenance personnel at international locations

Lower volumes of core metal washing wastewater

Waste reduced 96%

Waste water from the washing of release agents*3 in the steering wheel core bar process has been reduced with the introduction of oil separators. This resulted in a 96% decrease in waste material. The waste liquid discharged in this process includes very small amounts of oil, and previously all of this liquid was treated as waste. Now, by filtering this liquid with a membrane that allows water but not oil to pass, oil and water are separated based on the properties of the waste liquid. As a result, only the oil that does not pass through the membrane needs to be treated as waste.

  • *3 Chemical agents used to smoothly remove products from dies.
Lower volumes of core metal washing wastewater
Reduction in product packing material during distribution

Annual reduction targets are set for the amount of packing material used during product transport, and we continue to make improvements. In FY2016, we raised the utilization rate of washing machines for reusable containers to keep these containers clean. This reduced the use of packing materials to protect products from getting dirty. We were also able to reduce the number of containers themselves by increasing the packing density in reusable containers, leading to reductions in packing material. We will continue kaizen activities that aim to both maintain product quality and reduce waste.

Percentage decrease in the amount of distribution packing material used per sales unit
FY2016 (Compared against 2012)

  • Toyoda Gosei Co., Ltd. *411%increase
  • *4 Shipping of spare parts increased with the effects of disaster, and the amount of packing material increased.

■Amount of distribution packing material used/Amount used per sales unit (index)*4

Toyoda Gosei Co., Ltd.
(range: delivery logistics, in-process logistics, procurement logistics)

  • *5 Amount used per sales unit (index) is a figure obtained taking FY2012 as 100

Decreased water usage and effective utilization

Aggressive efforts are being made to identify loss and make improvements in order to reduce water usage volumes. One such effort was to review the rubber material cooling method in the Haruhi Plant. By installing freezers, we are able to reuse water that was previously discarded, reducing water consumption.

We will continue these efforts with a renewed awareness of the importance of water.

Percent decrease in water usage volume per sales unit
FY2016 (Compared against 2012)

  • Japan, consolidated14%decrease
  • Toyoda Gosei Co., Ltd.*62%decrease
  • Overseas affiliates25%decrease
  • *6 We have set individual targets for each year to achieve the FY2020 targets, but we did not reach the target for FY2016. In FY2017 we are trying to achieve further reductions tracking fluctuations in sales.
■Water use and water use per sales unit (index)*7

Japan, consolidated

Japan, consolidated

Toyoda Gosei Co., Ltd.

Toyoda Gosei Co., Ltd.

Overseas affiliates

Overseas affiliates
  • *7 Water use per sales unit (index) is a figure obtained taking FY2012 as 100