August 17, 2012

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Energy Huntsville Forum

TABC 1971

CAPTIN 1985

TMMK1988

TMMC 1988

BODINE1990

TEMA1996 TMMWV

1998TMMI1999

TMMAL2003TMMBC

2004

TMMTX 2006

SIA 2007

TMMC 2 2008

BODINE2005

$21+ Billion Invested

40,000 Direct Employees

TMMMS2011

Toyota Manufacturing in North America

Vehicle Plants - 7

Unit Plants - 5

Engine Plants - 2

Regional HQ

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TMMAL Overview – Company Profile

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Foundation: June 1, 2001

Investment: $700 million (by Spring 2014)

Location: Huntsville, AL

Plant Size: Land 200 acres Building 1.08 million sq ft

4-Cyl4.0L V-6

5.7L & 4.6L V-8

Toyota Property Line

Employees: 1,150 (by Spring 2014)

Engines 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)

                             

                             

                             

                             

                             

                             

Capacity 146,000/yr 144,000/yr 216,000/yr

SOP Aug. '05 Dec. '06 (3UR), March '09 (1UR) Sept. '11

Stats   24 valve 245 HP32 valve 381 HP /

32 valve 310 HP16 valve 182 HP / 16 valve 178 HP

Customers TMMBC, TMMTX TMMI, TMMTX TMMK, TMMC, TMMI, SIA

NEW 3.5L V-6

What Makes Toyota Different?

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• Empower Team Members

• What Gets Measured Gets Done

• Never Stop Improving

TMMAL Environmental Team

What is the Environmental Team?

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• 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

Regular Environmental Activities

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Process Checks DAILY

Kamishibai Checks WEEKLY

Team, Management Meetings

MONTHLY

Audits SEMIANNUAL

Kaizen Blitz SEMIANNUAL

Daily Process Checks

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• 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

Kamishibai Checks

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• 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

紙芝居 = “paper drama”

•Form of Japanese storytelling

•Often shared with elementary-age children

Team & Management Meetings

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• 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

Semiannual Environmental Audits

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• 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

Semiannual Kaizen Blitz

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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

Semiannual Kaizen Blitz

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• 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

Semiannual Kaizen Blitz

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FY12 Energy Reduction

1,069,5321,175,400

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

Target Actual

Kil

ow

att

Ho

urs

123,662 kwh, $8,656 annual savings by replacing outside lighting

283,500 kwh, $19,845 annual savings using compressed air actuators in production areas

Semiannual Kaizen Blitz

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Compressed Air Actuators13 valves not being

used in production areas• 63 hours/week• Estimated Annual Savings:

– 283,500 kwh/year– $19,845 / year

Semiannual Kaizen Blitz

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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

Payback = 2.75 yrs

Energy Reduction = 123,662 kwh/yr

Old

New

Semiannual Kaizen Blitz

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FY12 Water Reduction

411,000

655,000

0

200000

400000

600000

800000

Target Actual

Ga

llo

ns

630,000 gallons saved using Nano Filtration system to recover 70% of lost water

Semiannual Kaizen Blitz

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6/7 cycles

1/7 cyclesNano Filter

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

Semiannual Kaizen Blitz

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FY12 Waste Reduction

27,000

62,000

0

10000

20000

30000

40000

50000

60000

70000

Target Actual

Kil

og

ram

s

More than $70,000 savings identified through improved waste recycling opportunities

Semiannual Kaizen Blitz

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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

Summary

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• Empower Your Team Members

• What Gets Measured Gets Done

• Never Stop Improving

Any questions?

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