Environmental Report 2003 - Tokai Rika · 2012-10-05 · systems that enable drivers to convey...
Transcript of Environmental Report 2003 - Tokai Rika · 2012-10-05 · systems that enable drivers to convey...
Environmental Report 2003
Pro-environment activities are more commonly considered and carried out all over the world. To comply with
the EU Directive on end of life vehicles (ELV), Tokai Rika has made company-wide efforts to address the ELV
regulations since 2002. Similarly in Japan, automotive recycling regulations will become effective in 2004.
Carrying on global production operations, Tokai Rika will continue to set environmental targets and be an
environment-friendly organization for all of the people in the world.
Our environmental activities are planned well in advance so that there is always sufficient time for us to take
action to meet legal requirements and directives in a deliberate manner. As planned, last year, we
demolished incinerators to eliminate dioxin emissions. Another target, “zero emission,” was accomplished
one year earlier than our original target date. To reduce CO2 emissions, we have started to use energy-saving
equipment, such as fuel cells and co-generation systems. For the reduction of hazardous material use, we
will actually start applying new technologies to some products in order to totally eliminate lead and
hexavalent chromium from all of our products in the future. Regarding soil and groundwater contamination,
we have shared information with the local communities in the past, and we will continue collecting data
relevant to such contamination and look for further preventive actions whenever possible.
The Tokai Rika Group will commit to continually improve our environmental activities and performance
while sharing information with public. I would like to ask all interested parties for continuous support.
Yoshihei Iida
President,
Tokai Rika Co., Ltd.
We will promote pro-environment actions in accordance with our business philosophy and action guidelines.Main action items: Energy and resource conservation, recycling, waste reduction, control of chemicals, etc.
We will comply with laws, fulfill commitments made to our local communities and customers and voluntarily establish environmental objectives and targets to support prevention of pollution.
We will establish an environmental committee and implement activities for continual improvement of the environment.
1
2
3
Main Activities Key Activities from 2001 to 2005
Establishment andImplementation ofEnvironmentalManagement System (EMS)
1
Tokai Rika Environmental CommitteeChairman:Yoshihei Iida, President
Headquarters and Plant Environmental CommitteeVC Center Environmental Committee Production and Test Engineering Building Environmental Committee Office Building Environmental Committee Head Plant Environmental Committee Nishibiwajima Plant Environmental Committee Toyota Plant Environmental Committee Otowa and Hagi Plant Environmental Committee
CommitteeSecretariat
(Revised in June 2003)
Product Environmental Committee
ELV Subcommittee
IMDS Subcommittee
Lead Free Solder Project Hexavalent Chromium Free Project ELV STEP 2 Project
●Toyota Group EMS: Environmental assessment indices are reported monthly. ●Tokai Rika Group EMS: Promotion of environmental activities is expanded to the subsidiaries and suppliers.
Compliance withRelevant Regulations2
●Each facility maintains and evaluates a list of relevant regulations to ensure compliance. ●Hazardous Material Control & Safety Manager, Pollution Control Manager and other qualified specialists (e.g. specialists on vibration and noise regulations) are appointed.
Prevention ofGlobal Warming3
●In-house power generation rate is to increase by cogeneration system installation. ●Energy conservation actions are taken for equipment with high energy consumption. ●Electricity is shut off throughout the company building during holidays.
Control andReduction ofHazardous Materials
4
●Hazardous materials are identified and controlled. ●Emissions / discharges are reduced.
Waste Reduction andResource Conservation5
●Zero-Emission actions are promoted. ●Measures to decommission incinerators are taken (in March 2003). ●Yield of resin is to be improved. ●Processed material wastes are to be decreased.
EnvironmentalManagement Programsfor Products
6
●A system is established to control hazardous materials contained in the products. ●Countermeasures are to be developed and taken for hazardous material control, such as development of alternatives. ●Use of recyclable materials and design of light-weight products are promoted.
Improvement inLogistics7
●CO2 emissions from transportation are to be reduced. ●Packaging materials usage is to be reduced.
Involvement ofSubsidiaries8
●Domestic and overseas subsidiaries are to establish an EMS and become ISO 14001-certified.
Cooperation withSuppliers9
●Activities of supplier association: energy conservation, waste reduction, and hazardous material reduction. ●Green procurement: Purchase of eco-products is encouraged, and supplier evaluation criteria are to be defined.
PR, education andcontributions to society10
●Participation in volunteer activities is encouraged. ●Environmental reports are regularly published, and environmental information is shared with public.
Production Environmental Committee
Overseas Base Environmental Liaison Committee
Green Procurement Committee
Legislation Compliance Subcommittee
Energy Saving Subcommittee
Resource Productivity Improvement Subcommittee
■Current Status of ISO 14001 Certification
Certified before 2001 Certified in 2002 Certified in 2003
Plants in Japan
Sales Offices in Japan
Asia
The Americas
Europe
Headquarters / Main Plant
Nishibiwajima
Toyota
Otowa,Hagi
Tokyo, Osaka, Hiroshima
Rica Auto Parts Co., Ltd.
(Taiwan)
TRP, Inc. (the Philippines)
TRMI, Inc. (U.S.A.)
Renewal audit
Renewal audit
Shinchang Electrics Co., Ltd.
(South Korea)
TRAM, Inc. (U.S.A.)
TAC Manufacturing, Inc. (U.S.A.)
TRIN, Inc. (U.S.A.)
TRB (U.K.)
TRT (Thailand)
MINDARIKA (India)
TRCT (China)
TSB (Thailand)
TRBR (Brazil)
QSS (Canada)
TRCZ (Czech)
Items
1)Pollution prevention and
resource conservation /
reuse activities
2)Upstream, downstream costs
3)Management activities
4)R&D activities
5)Community activities
6)Remedies for environmental damages
■Investments and Expenses
Investments
Subtotal
Total
Expenses
1,289.5
215.5
221.9
165.5
0.0
102.8
74.3
28.4
34.8
843.2
120.7
70.4
107.4
0.0
0.0
25.2
0.6
122.0
446.3
(Unit: million yen)
■Economic Effects of Environmental Protection Activities
607.7―
Effect
Total
Volume(ton/year)
Value of effect (million/yen)
410.0
171.4
26.3
8,636t
1,296t-CO2
675t
Sales of recycled materials (iron, nonferrous metals, plastics, oil, etc.)
Cost reduction by energy saving (CO2 reduction volume)
Reduction of waste disposal costs and other relevant costs (reduction of waste amount)
Second surveillance audit
※We spent approximately 1.29 billion yen (0.5% of Sales) on environmental protection activities from April 2002 to March 2003. It was utilized more for operating costs of equipment than equipment itself.
※Activities to support recycling and disposal of our products and packages, environment-friendly purchasing (green procurement), etc.
EnergyElectricityHeavy oilParaffin oilOil gasCity gasCogeneration
: : : : : :
80,521 MWh116 k
19 k 107 t
5,811,000 m3
3,983 MWh
OthersC h e m i c a l s (regulated)PaperPackaging paper
: : :
159 t 1,704 million sheets260 t Recycling : 10,773 t
Raw MaterialsResin materialsUrethaneZincAluminiumMagnesiumIronCopperSolder materialGlass
: : : : : : : : :
8,244 t533 t
2,738 t439 t
1,942 t9,566 t2,896 t
30 t42 t
Water ResourcesCity waterIndustrial waterGroundwater
: : :
249 km3
104 km3
311 km3
Air EmissionsCO2: 67,128 t-CO2
Air emission (from logistics)
CO2: 1,310 t-CO2
Drainage
Recycling
SewageWaste Water
: :
87 km3
440 km3
WasteLandfillProcessed materialsWaste materials (Total)
: : :
23 t901 t
11,697 t
ProductionProduction
ProductProduct
Environment-Friendly Product Design
Tokai Rika considers environment-friendly production from the design phase. Whenever possible, we always try to develop
products free of hazardous materials. We thoroughly identify materials used in our products for proper control. For fuel
efficiency improvement, some products become more compact or lighter or use higher voltage.
Tokai Rika makes a large contribution to the creation of a high quality of life with automobiles through the production and sales of products that faci l i tate better communication between people and automobiles. Examples are human-machine interface systems that enable drivers to convey their thoughts to the vehicles, security systems to protect automobiles from theft, and safety systems to save lives.
By June 2006 Elimination of hexavalent chromium
From July 2005 Elimination of lead
Mid-Term Target
Trivalent Chromium as an Alternative
Lead-Free Soldering
■Lead-free reflow soldering products (used since August 2003)
As the first step, lead-free reflow soldering has been used on printed circuit boards (PCB) for new products produced since August 2003.
■Corrosion resistance in salt-water spray test
Plating only
Galvanization w/ trivalent chromiumGalvanization w/ hexavalent chromium (yellow)Galvanization w/ hexavalent chromium (white)
Time for the formation of white rust ※Red rust for the data on plating only
Galvanization with trivalent chromium is more resistant than hexavalent chromium (white) but less resistant than hexavalent chromium (yellow). The difference between the white and yellow coatings is generated from the content of hexavalent chromium (yellow coating contains approximately eight times larger hexavalent chromium than the white coating).
Products ofTokai Rika
Human-Machine Interface Systems
Security Systems Safety Systems
Exterior Customized Products Electrical Appliances& Devices
Wheel covers Consumer products Rotary sensors for motors of electric vehicles
Multi-function switches SeatbeltsSMARTKEY system
■Relationship between ELV, IMDS and other regulations
Tokai Rika (supplier)
③
①
② ④
Regulations
ELV regulation
Materials/ Parts
Manufacturers
Request for information on legal co- m p l i a n c e , i n c l u d i n g ELV
Sharing (reporting) information via IMDS
IMDS
Parts Selection Automakers
■IMDS Data Flow
Register materials and enter chemical substances contained in materials
Built a tree of components and materials
Enter recycling information and contact persons
Distribute data sheets within the company (internal approval)
Send data sheets to customers
Resend sheets after modification if rejected
O b t a i n approva l f r o m customers
Development of Switches for 42V
■Lead-free reflow soldering products
Hybrid switch
High-speed direct switch
Magnetic arc-suppressing switch
Contactless switch
Cogeneration System in Ena Tokai Rika (fully operational since August 2003)
Energy Saving on Lighting
March 2006 5% reduction from 1990
・Environmentallynvironmentally (CO2 emissions reduction)
・Economicallyconomically (improvement of profitability)
・Effectively (Targets of streamlining business operations set by METI※)
※Annual 1% improvements proposed by Japan Ministry of Economy, Trade and Industry
3E Campaign
March 2011 10% reduction from 1990
Mid-term targets
60,61063,10964,442 60,992
57,579
67,044
■CO2 emissions by year
,90 …
,00
,01
,02
,03 …
,05
60,000
40,000
20,000
0
(t-CO2) TargetActual
■Cut-One System
Lighting fixture with two bulbs
No light when one bulb is removed
Dummy bulb (lighting circuit is installed inside)
High-efficiency fluorescent bulb (approx. 20% increase in lighting intensity)
Reflector (95% reflectance)This is a system to decrease electricity consumption by using only one bulb in a lighting fixture with two bulbs. Electricity consumption can be reduced without decreasing illumination by replacing one fluorescent bulb with a dummy bulb and the other with a high-efficiency fluorescent bulb (approx. 20% increase in illumination with similar electricity consumption), and installing a high-performance reflector (95%). This is a patent pending developed by Japan Energy Institute.
Reduce
Reuse
Recycle
■The Mechanism of Cogeneration System
Extra-high voltagesubstation
・Humidification for visor painting・Heat for visor painting
Painting of wheel coversSteam heater for dry furnace
Heating of plant
Steam
Steam
Steam
Hotwater
Coolwater
Coolwater
Coolwater
Coolwater
Hot water boiler forvaporizer
Air conditioning
Compressor inletair cooling
Cool water supply fordie temperature control equipment
Chiller alternative cool water supply for visor painting booth
Cool water tank
Steam heat exchanger
Fan coil unit
Cool water supply tank
Existing steam boiler
Micro gas turbine
Diesel engine
Diesel engine
Heavy oilFuel
Exhaust gas steam boiler
Exhaust gas steam boiler
Exhaust gas steam boiler
Steam absorption chiller
Steam absorption chiller (existing)
CGS building Energy building Process
Utility facility at the plant
Electric power company
Environment-Conscious Production
Tokai Rika’s production is environment-conscious. We promote pro-environment activities, such as energy saving for the
reduction of CO2 emissions, reuse and recycling of waste and thorough control and reduction / elimination of chemicals.
Environmentally Economically
Effectively・Reduce
・Reuse
・Recycle
3R Campaign
Landfill95% reduction from 1995 by March 2004
Processedmaterials
66% reduction from 1990 by March 2006
Discontinued/unwantedmaterials
50% reduction from 1990 by March 2006
Mid-Term Targets
Total emission ofPRTR-listed materials
20% reduction from 2000 by March 2006
Mid-Term Targets
,90 … …
,01
,05
▲66%
,02
2,000(t)
1,000
0 ,03
1,479
1,918
901
639
979
■Waste designated to landfill by year
■Processed material waste
(t)
,90 … …
,99,00
,05
,01
0
5,000
10,000
15,000
■Discontinued/unwanted materials
10,089 10,717
6,837
,02
11,697
,03
8,138
13,673
8,273
TargetActual
,90 … … …
,95
,01
,05
▲95%
,02
2,000(t)
1,000
0 ,03
120
1,190
2,023
23 4454
Molding of Recycled Materials
※PRTR (Pollution Release and Transfer Register): a system for collecting and releasing data that shows which hazardous chemicals have been released to the environment from where and how much, and how much was included in waste discharged from the organization.
※MSDS: Material Safety Data Sheet
■Recycling Molding Equipment
High-cycle molding machineHigh cycle and energy saving are realized with a motor-driven mold clamping unit.
High-yield dieSprue runner waste is reduced by using a longer injection nozzle with a smaller diameter. The air in the long core is air-cooled to prevent overheating caused by high cycle.
Sprue runner crusherCassette type crusher Crushing blade for thin sprue runners
Before crushing After crushing
TargetActual
0
10
20
30
40
50
60
70
80(t) ■Discharge Amount of PRTR-listed Materials
73.9
,96 ,99 ,00 ,01 ,02 … … ,05
18
28.1
2027
15
■Transfer Amount of PRTR-listed Materials ※Unit:kg/year
Usage158,996
Air19,966
Treated on site(Not subject to PRTR)23,172Facility Site
Water ways300
Waste13,555
Recycled6,362
Products95,641
Raw materials Supplementary materials
15 chemicals
Zero Emissionachieved
The number of chemicals listed increased from 174 to 354
,99
(t) 400
200
0
344
,00
268
,01 …
…
264
,02
260
,05
265
(t-CO2) 1,600
800
0 ,99 ,00 ,01 ,02 ,05
1,3291,406
1,321 1,310 1,226
■Packaging material usage
■CO2 emissions from transportation process
Safety check
Green Procurement Guideline
Environment-Conscious Procurement and Logistics
Tokai Rika promotes the purchase of more environment-friendly parts, raw materials and office supplies to be a pro-
environmental organization at a higher level. We also consider the environment to transport our parts at the logistic stage.
People, Communication and Contributions
Tokai Rika is committed to enhance our Associates’ environmental awareness by encouraging them to acquire expertise and
qualifications and by continuously providing environmental awareness training. In addition, all Associates carry out preventive
activities to eliminate accidents from the workplace for occupational injuries and illness for the enhancement of Associates’ health.
TargetActual
※Hiyari-Hatto suggestions: Suggestions regarding fearful or startling incidents that did not become major accidents but need to be informed for the prevention of accidents in the future.
※Kiken-Yochi:to detect dangers at work
★
SubsidiaryISO 14001-certified company Affiliate
TRCZ s.r.o.Tokai Rika Belgium N.V.
Tianjin Tokairika Automotive Parts Co., Ltd
Tokai Rika(Thailand) Co., Ltd.
MINDARIKA PRIVATE LIMITED
TRB Limited
Thai Seat Belt Co., Ltd. TRP,Inc. TRBR Industria e Comercio Ltda.
TRIN,Inc.
TAC Manufacturing,Inc.
TRAM,Inc.
Quality Safety Systems Company
TRMI,Inc.
Wuxi Risho Technology Co., Ltd
Shinchang Electrics Co., Ltd
STF Co., Ltd
Rica Auto Parts Co., Ltd
North America
Activities at the TRAM Group (U.S.A.)
TRAM, TRIN and TAC obtained multiple site certification in February 2003. TRMI transferred their certification to the TRAM Group’s certif ication last September.
TRAM TAC
TRMI TRIN
The main recycling center
The scene of ISO 14001 certification
Activities at TRB (U.K.)
TRB supplies various types of switches to OEMs. They obtained their ISO 14001 certification in December 2002. TRB became the first 14001-certified plant among our European subsidiaries.
Activities in Overseas
As members of the Tokai Rika Group, our overseas subsidiaries have worked toward ISO 14001 certification, by establishing
an organization for environmental management activities and implementing audits. By March 2003, 7 of the 13 overseas
subsidiaries have received ISO 14001 certification.
Asia
Europe
3-260 Toyota, Oguchi-cho, Niwa-gun, Aichi 480-0195, JapanTEL: (0587) 95-5211 / FAX: (0587) 95-1917
Environmental Committee Chairman: Yasuhiro MiyakeManaging Director, Member of the Board
●Achievement of “Zero Emission”
●New Recycling Area
Environmental ActivitiesEnvironmental Activities
ISO 14001 Audit Findings
●First Renewal Audit
Environmental Events and Activities with Local CommunityEnvironmental Events and Activities with Local Community
●Meeting with Oguchi Residents
●Fire Drill for Monosilane Gas Leak
Major non-conformances
Minor non-conformances
Observations
0件
0件
0件
ISO 14001 Audit Findings
ISO 14001 Audit FindingsISO 14001 Audit Findings
●First Renewal Audit
Major non-conformances
Minor non-conformances
Observations
0件
0件
0件
Environmental Committee Chairman: Kazuhisa KubotaMember of the Board
●Energy Saving
●Emergency Drill
●Reduction of Electric Usage
●Sun Block Film Installation
●Waste Reduction
Environmental ActivitiesEnvironmental Activities
Environmental TrainingEnvironmental Training
Environmental Events and Activities with Local CommunityEnvironmental Events and Activities with Local Community
●Meeting with Nishibiwajima Local Residents
Environmental Events and Activities with Local Community
●“Love! Nishibi Day”
●“Zero Waste Campaign”
●Seatbelt Awareness Campaign
Environmental Activities
Environmental Training
Environmental TrainingEnvironmental Training
●Oil Spill Dril
Environmental Activities
480 Izumi-machi, Nishibiwajima-cho, Nishikasugai-gun, Aichi 452-0015, JapanTEL: (052) 501-8141 / FAX: (052) 501-0233
Environmental Activities at Tokai Rika Plants
Environmental Training
Environmental Committee Chairman: Hiroki IwasaMember of the Board
Environmental Activities
ISO 14001 Audit Findings
Environmental Events and Activities with Local Community
ISO 14001 Audit FindingsISO 14001 Audit Findings
●First Renewal Audit
Major non-conformances
Minor non-conformances
Observations
0件
0件
0件
ISO 14001 Audit FindingsISO 14001 Audit Findings
●First Renewal Audit
Major non-conformances
Minor non-conformances
Observations
0件
0件
0件
ISO 14001 Audit Findings
Environmental Committee Chairman: Takaoki Tsuchiya Member of the Board
Environmental Activities
Environmental Training
Environmental Events and Activities with Local Community Environmental Events and Activities with Local CommunityEnvironmental Events and Activities with Local Community
●Meeting with Local Residents
●Cleanup Activities by the Tokai Rika Academy Students
●Energy Saving Activities
●Reduction of Waste Incineration
Environmental ActivitiesEnvironmental Activities
Environmental TrainingEnvironmental Training
●Awareness Training for Waste Reduction
Environmental Training
●Installation of Lighting Fixtures with Inverters
●Reduction of Sludge in Wastewater
●Thorough Waste Sorting
Environmental ActivitiesEnvironmental Activities
●Participation in Local Events
Construction site
Otowa Plant
Hagi Plant
2-47-1 Konosu-cho, Toyota, Aichi 471-0836, JapanTEL: (0565) 28-1141 / FAX: (0565) 28-5792
Otowa Plant: 1 Aza-Hirayama, Oaza-Akasaka, Otowa-cho, Hoi-gun, Aichi 441-0295, Japan TEL: (0533) 88-4111 / FAX: (0533) 88-2244Hagi Plant: 1-3 Aza-Nakayama, Oaza-Hagi, Otowa-cho, Hoi-gun, Aichi 441-0201, Japan TEL: (0533) 88-7051 / FAX: (0533) 88-7055
Environmental TrainingEnvironmental Training
This environment report is:• Made out of 100% recycled paper;• Printed in biodegradable ink made from soybeans with reduced volume of petroleum-based solvents;• Printed with water-free method to avoid the use of humidifying water with hazardous material; and• Printed by ISO 14001 certified printing company.
■For inquiries on this report and our environmental activities, contact:
Tokai Rika Co., Ltd.Environment Administration Department,Production Facilities and Environment Division3-260 Toyota, Oguchi-cho, Niwa-gun, Aichi 480-0195, Japan
TEL (0587) 95-9002 FAX (0587) 95-1261
URL http://www.tokai-rika.co.jp/
E-mail [email protected]
Tokai Rika Co., Ltd
August 30, 1948
¥15 billion (as of March 31, 2003)
Automotive switches, lock/key sets, seatbelts, airbags, shift levers, electronic
parts, steering wheels, connectors, mirrors, resin wheel covers, ornaments, child
safety seats, household electric appliances, electronic medical devices,
measuring instruments, electronic parts for agricultural machinery, and
construction vehicle parts
Subsidiaries ―4 (Japan), 13 (Overseas)
Affiliates ―4 (Japan), 5 (Overseas)
Non-consolidated ―5,411,
Tokai Rika Group Consolidated ―8,452 (as of March 31, 2003)
Non-consolidated ―¥218.2 billion,
Tokai Rika Group Consolidated ―¥243.9 billion (as of March, 2003)
Name
Establishment
Capital
Major Products
Group
Employees
Sales
Corporate Profile