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ENVIRONMENTAL ASPECTS Risk reduction activities Pokayoke Pit Project Pokayoke is a Japanese term, which loosely translated means a ‘foolproof back-up’. The Pokayoke Pit Project was initiated in 2008 to reduce the risk of accidental spillages of contaminated waste water from TSAM’s manufacturing facility into the stormwater drainage system, which feeds into the canals surrounding the Prospecton Plant and then into the nearby Isipingo River. The project was initiated following a number of incidents in FY06 and FY07 which resulted in effluent spills into the storm water system. The aim of the project was to provide a back-up ‘safety net’ system that would contain accidental spillages from high risk areas of the plant. The Pokayoke Pit containment system involves the construction of underground waste water storage pits that are linked to cut-off trenches constructed around high risk areas. These trenches, coupled with bunds, are strategically positioned to capture and direct any effluent spills into the Pokayoke Pits before they reach the stormwater drainage system. The spilled waste water is pumped from the Pokayoke Pits back into the effluent system and then to the Waste Water Treatment Plant, where it is treated before being released into the municipal sewerage system. The project scope included the main Waste Water Treatment Plant, Press Plant, Resin Plant and Paint Plant. The Waste Water Treatment Plant had two aspects; secondary containment and emergency storage. Secondary containment involved the construction of cut-off trenches around the perimeter of the plant and linked to Pokayoke Pits. Emergency storage required a change in operational procedures and the using of one receiving dam only for normal operations while the second dam remains as a backup for emergency conditions. A high level link between the two dams that can handle maximum inflow volumes of 91m3 /hr was constructed for such emergencies. The Press Plant had an epoxy-coated bund constructed around the existing effluent pit, the existing effluent pump was upgraded, 34 Toyota South Africa Motors Sustainability Report 2010 Resin Plant Pokayoke Pit. The trench, coupled with bunds, captures and directs any effluent spills into a waste water storage pit before they can reach the stormwater drainage system. an additional back-up pump installed and a dedicated effluent line from the Press Plant to the Waste Water Treatment Plant was constructed. The Resin Plant improvements included the construction of a 19m3 Pokayoke Pit linked to the existing effluent pit, the construction of an epoxy-coated bund around both pits, upgrade of the existing effluent pump and the installation of a back-up effluent pump. High-level alarms in the pits are linked to the Press and Resin Plant offices, as well as plant surveillance. The Paint Plant had four aspects to the project. Chemical offloading areas saw the construction of cut-off trenches, bunds Pipe Bridge Project TSAM identified a risk regarding pipes carrying bulk fuel. The pipes ran under the road, onto the roof and into the plant. There was no easy access to the roof to inspect the pipes, and any leaks would not be contained. TSAM implemented the following corrective actions: • Two pipe bridges were installed, each with a foot bridge to allow for inspections of the pipelines along the bridge and on the roof; • Underground pipes were replaced with above ground pipes placed in and sumps linked to effluent pit areas. All entrances and exits were re-assessed with some being bricked-up to improve containment. At all other doors, sealed bunds constructed to withstand impacts of vehicular traffic were installed. The bunding at the ED/Phosphate and Degrease process areas was raised and sealed with chemical-resistant epoxy coating. At the sludge pool area bunds and cut-off trenches were constructed. New centrifugal pumps were installed and linked directly to the effluent pit along the east wall. Construction work started in August 2009 and the project was completed in March 2010. Above ground pipes have been placed in containment trays. containment trays within the pipe bridge, with drainage into the bulk tank bunded areas, so any leaking product can be contained; and • Bulk fuel pipelines were colour-coded for ease of identification.
Greening activities National Arbor Week National Arbor Week is celebrated every year during September, and serves to promote awareness of the need to plant and maintain indigenous trees throughout South Africa, especially for the many disadvantaged communities living in barren areas. TSAM planted trees, including the tree of the year Haleria lucida, on 4 September 2009 to celebrate National Arbor Week. Delegates representing senior management, employees and unions attended the event. TSAM handed out more than 1 000 small indigenous tree seedlings to employees from the Prospecton plant to plant at their homes, and to three schools around Durban. Plant Greening Project TSAM planted 200 trees in specific areas around the Prospecton Plant as part of a greening campaign that will benefit the whole neighbourhood. 200 indigenous trees were planted around the Prospecton Plant. TSAM planted indigenous trees to celebrate National Arbor Week. Raising environmental awareness The TSAM Safety, Health �� and Environment (SHE) � �� The theme of this issue of ECO Awareness is Significant Environmental Activities / Processes. Department regularly releases All our production processes have the potential to have one or more of the following impacts on the environment: Eco Awareness newsletters o Noise o Waste water o Landfill waste o Ground and surface water pollution o Air pollution as part of a drive to inform and TSAM has through its ISO 14001 Environmental Management System (EMS) conducted a risk assessment of all possible environmental impacts in all areas under normal operating educate TSAM employees and conditions, abnormal conditions (e.g. breakdowns / shutdowns) and emergency situations (e.g. spillages / floods) to identify those impacts which have a significant effect on the environment. contractors about environmental There are a number of significant environmental activities / process areas on site. They are identified through ‘significant process signage’ and the equipment in the significant areas is identified by ‘significant equipment signage.’ The following is a list of activities / processes generally considered to be matters. The newsletters also environmentally significant: o All activities / processes which pose a contamination risk to storm water and waste water systems o Chemical storage and offloading areas seek to inform employees and o Underground and aboveground bulk fuel storage tanks o Chemical process tanks o Paint spray booths and sludge pools o Waste water sumps and pits o Waste water treatment plant o Hazardous waste areas. contractors about significant Significant environmental activities / process areas are controlled through work instructions, training of employees and contractors working in these areas and through inspection checks. These controls are continuously being improved upon to reduce the environmental impacts and the risk of environmental incidents. environmental activities and Please report any leaks, spillages or overflows observed in these areas to the Environmental Champion responsible for your department or to the SHE Department. processes and how TSAM seeks to mitigate environmental impacts through them. �� Toyota Zone, the TSAM corporate magazine with a circulation of 35 000 copies, releases a ‘green edition’ once a year. The whole edition focuses on sustainability and environmental issues, and is printed on environmentally friendly paper. TSAM aims for at least one environmentally focused article to be featured in each edition of the magazine. Appendix Status of ISO 14001 certification The TSAM production facility was certified compliant to the ISO 14001 EMS standard in 2002 and has retained its certificate ever since. Sandton achieved certification for the first time in 2004. Over the years, both the TSAM production facility and Sandton have maintained certification. Within the reporting period the TSAM production facility was recertified in 2008 and Sandton was recertified in 2009. ENVIRONMENTAL ASPECTS Toyota South Africa Motors Sustainability Report 2010 35
Page 2 and 3: About this Report This is the sixth
Page 4 and 5: MESSAGE Executive message from the
Page 6 and 7: SPECIAL FEATURE Toyota South Africa
Page 8 and 9: SPECIAL FEATURE 30 years of market
Page 10 and 11: ABOUT THE COMPANY About the Company
Page 12 and 13: ABOUT THE COMPANY The Toyota Way is
Page 14 and 15: ABOUT THE COMPANY The Toyota Code o
Page 16 and 17: ENVIRONMENTAL ASPECTS Figure 8 Glob
Page 18 and 19: ENVIRONMENTAL ASPECTS The TSAM Four
Page 24 and 25: ENVIRONMENTAL ASPECTS Energy/Global
Page 26 and 27: ENVIRONMENTAL ASPECTS Reduction of
Page 28 and 29: TMC’s commitment to hybrid techno
Page 30 and 31: ENVIRONMENTAL ASPECTS Sandton waste
Page 32 and 33: ENVIRONMENTAL ASPECTS Atmospheric Q
Page 34 and 35: ENVIRONMENTAL ASPECTS Environmental
Page 38 and 39: SOCIAL ASPECTS Customer satisfactio
Page 40 and 41: SOCIAL ASPECTS Relations with Emplo
Page 42 and 43: SOCIAL ASPECTS Human rights TSAM’
Page 44 and 45: SOCIAL ASPECTS TSAM’s Graduate Tr
Page 46 and 47: SOCIAL ASPECTS SPECIAL FEATURE Reco
Page 48 and 49: SOCIAL ASPECTS Fatalities There wer
Page 50 and 51: SOCIAL ASPECTS Occupational health
Page 52 and 53: SOCIAL ASPECTS Relations with Busin
Page 54 and 55: SOCIAL ASPECTS is made to assist in
Page 56 and 57: SOCIAL ASPECTS of the Kavango-Zambe
Page 58 and 59: Independent Assurance Statement To
Page 60 and 61: Global Reporting Initiative Index G
Page 62 and 63: Glossary of terms and acronyms 3R R

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