Toyota South Africa Sustainability Report 2008 - Automotiveonline ...

More documents

Recommendations

Info

Sustainability Report_14-10-2008:Layout 1 10/14/08 2:43 PM Page 4 “Monozukuri” and the Cycle of Nature... Toyota’s World View and Our Mission “Cycles of Nature” All people and communities are subject to the natural cycles of the earth. Toyota is committed to undertaking “monozukuri” (manufacturing that strikes a harmonious balance with nature in order to carefully sustain the global environment). “Cycles of Industry” An industry creates new value, while spawning the birth of a new industry – such is the way of the cycles of industry. Toyota endeavors to be a driving force behind the development of sustainable industries. As we head towards 2020, our mission is to re-examine the relationships between nature and industry, and to contribute to finding a harmonious balance between the cycles of nature, and the cycles of industry. Two significant changes occurred at our operations at Prospecton during the reporting period. In 2002, we embarked on a five-year plant modernisation and expansion programme in order to meet expectations regarding the new Toyota Corolla, destined for European markets. The introduction of the 10 th Generation Corolla required that the Prospecton Plant be expanded to enable a volume capacity of 220,000 units per annum by the year 2009, an increase of 340% over the 50,000 units exported in 2006. To this end, FY’06 saw the final construction and commissioning of Paint Line 3, and the associated decommissioning of Paint Line 2, along with various other production and manufacturing plant changes. Significant enhancements have also been introduced in the vehicle assembly hall, body and chassis line. The resin component production facility has also been equipped with Toyota’s leading edge technology and boasts its own water based paint facility for the painting of bumpers. The focus of the improvements has been on uncompromising quality, improved efficiencies, increased capacity, cost competitiveness and beneficial environmental improvements. 4
Sustainability Report_14-10-2008:Layout 1 10/14/08 2:43 PM Page 5 Technical modifications alone were not sufficient to deliver the required quality, and to ensure buy-in from employees, a unique ‘Excellence in Customer Quality Challenge’ (E-CQC) was rolled out in May 2007. The aim of E-CQC was to create a quality mindset across the Toyota network, so that Toyota can deliver on the quality expectations of customers in the various markets into which the new Corolla will be launched. From a sustainability perspective, the E-CQC challenge emphasises engagement with all stakeholders in the life-cycle of the vehicle. Corporate Philosophy Toyota is committed to pursuing sustainability in three specific areas:technology (including research and development), manufacturing and social contribution. Our position in society is entirely dependent on achieving growth that maintains a balance between corporate activities and environmental conservation, as well as between vehicle volume and quality. In all our activities and all our interactions, our aim is to create harmonious and sustainable relationships with all our stakeholders, and to respect the environment in which we operate. Recognising that our success depends on responsible social development and the integrity of environmental systems, guidance has been developed to articulate how we contribute to these cornerstone business requirements. Sustainability principles have been core to Toyota’s business model and success since its founder, Mr Sakichi Toyoda developed the Toyota Precepts, which evolved into the Guiding Principles for the company. PAINT LINE 3 BENEFITS ECONOMIC, SOCIAL, ENVIRONMENTAL AND QUALITY OBJECTIVES Paint Line 3 was opened in 2006, and adopted the same advanced paint technology used in TMC’s nine paint plants in Japan, including the use of metallic water-borne paint for the top coat, which greatly reduces potentially harmful atmospheric emissions. Paint Line 3 is one of only five similar plants commissioned by Toyota Motor Corporation globally. The new paint facility represents an investment of more than R1-billion, the Black Economic Empowerment (BEE) component of which was approximately R250-million, and is a major part of Toyota’s 220K production programme. The full investment will total R2,4-billion. From an environmental perspective, the transition to water-borne paint technology in Paint Line 3 will see our current Volatile Organic Compound (VOC) emissions reduce from 80gm/m 2 to just 30gm/m 2 painted, which conforms fully with international standards. This will contribute to a 60% reduction in air emissions from the new plant, compared to our previous two paint plants. At full capacity, there will also be reduced electricity usage in terms of the cost per unit. Propane, used to fire the paint shop ovens, is replaced with methane-rich natural gas which has both environmental and economic benefits. Paint Line 3 also introduced significant quality benefits. The new facility created 4,000 job opportunities. Huge investment has also been made in training the people who work in the new paint plant. A total of 58 senior team members spent 60 person-months in Japan on training, at a cost of R12-million. A further 250 team members have undergone training locally over a period of five months. Toyota South Africa currently spends more than R70-million a year on direct training and skills development to support this increase in production capacity. Some other key sustainability results are: • 50% of expenditure on plant, machinery, services and civil engineering work was with local companies. • 60 contractors were involved in the project, 77% of whom had BEE status. • A 60% reduction in air emissions, especially VOC emissions. All exhaust gases from the drying ovens and all volatile solvent emissions are processed through a Regenerative Thermal Oxidiser (RTO) where they are burnt off with the assistance of a gas burner. Sustainability Report 2008 5
Page 1 and 2: COVERS:Layout 1 10/14/08 12:21 PM P
Page 3 and 4: Sustainability Report_14-10-2008:La
Page 5: Sustainability Report_14-10-2008:La
Page 55: COVERS:Layout 1 10/14/08 12:21 PM P

Toyota South Africa Sustainability Report 2008 - Automotiveonline ...

Create successful ePaper yourself

Delete template?

Save as template?