aim: zero emissions - Toyota

The production of vehicles, engines and transmissions in
factories inevitably has an impact on the environment. To
ensure that car manufacturing can make more with less,
Toyota developed its world-famous Toyota Production
System (TPS) several decades ago. Over the years, TPS
has also evolved to include new environmental targets.
It is now applied in Toyota’s production facilities all over
Europe.
toyota’s production system...
• eliminates waste
• reduces energy usage
• minimises use of raw materials
• delivers standardised quality
by...
• applying best practice in
all processes (“Yokoten”)
• continuous improvement
(“Kaizen”)
• going to the source to find the
facts (“Genchi Genbutsu”)
• just-in-time production, by
‘pulling’ products through the
production line
• active involvement from
all team members
10
Greener
manufacturing
in the Toyota Prius
Clean
manufacturing
Constant efforts to improve standards
throughout the workplace have radically
reduced the environmental impact of
production at our plants.
Since 2001:
• Total energy usage per car has
been reduced by 37% across all of
Toyota’s European manufacturing
plants.
• Water usage has been reduced in
Europe by 34%.
• Packaging waste has been reduced
through the full use of returnable or
recyclable packaging.
• Volatile organic compound
emissions per square metre of
painted surface have been reduced
by 21%.
Aim: zero emissions
through TPS
For example: Toyota’s vehicle plants in both the U.K. and France, have achieved the
ambitious target of delivering zero waste to landfill.* Applying TPS principles, staff
carefully examined how production waste was created, and invented appropriate
solutions to reduce, reuse or recycle all the ‘waste’ materials generated. This has resulted
in a 73% reduction of waste going to landfill since 2001.
The manufacturing process for the new Prius model has been organized to reduce the amount of energy needed
for building the car. CO 2 emissions during the manufacturing process are cut by 31% compared to the previous
Prius production plant. Special Eco-plastic made from plants to provide floor mats is used. This further reduces CO 2
emissions during manufacturing. The batteries are smaller and more efficient, resulting in 33% less CO 2 emissions
during manufacturing when compared to the previous generation Prius.
the toyota prius is 90% recycable!
* Zero waste to landfill: less than 3% of 1997 amount of waste disposal to landfill