MATERIALEnvironmental Report 2002

ISO 14001 Cert i f icate of Registrat ion

Environmenta l Educat ion System

Aimed at : Deta i l s

New employeesFundamenta ls of env ironmenta l protect ionEnvironmenta l pol ic ies of AIS IN AWImportance of observ ing ru les

Newly appointedmanagement superv isors

Environmenta l problemsEnvironmenta l management proceduresRoles and respons ib i l i t ies of workers

Workers inenvironment-re lated fac i l i t ies

Operat ion and checkingMaintenanceDeal ing with abnormal i t ies and emergencies

persons

Trends in the Number of People Complet ingInterna l Auditor Tra in ing

01997

18

1998

127

1999

175

2000 2001

211

50

100

150

200

250223

2002

230

year

AmountItem

1. Business costs

2. Upstream and downstream costs

3. Management costs

4. R&D costs

5. Social costs

6. Environmental harm costs

1.1 billion yen�

�

900 million yen

100 million yen

2.7 billion yen

100 million yen(Note 1) ー

4.9 billion yen

Preventing pollution, e.g. air, water and soil pollution

Energy saving

Recycling and waste disposal

Collecting and remanufacturing products, recycling packaging

Operating EMS, environmental education, environmental monitoring and measuring

Research and development to reduce environmental burdens

Nature protection and tree planting

Repairing environmental pollution damage

TotalNote 1: ー denotes less than 100 million yen

Environmental Conservation Costs

Quantitative benefits Economic benefitsItem Major challenges

Global warming prevention

Waste reduction

(Note 2) 3,060c-t(Note 2) 20ton

(Note 3) 37,780ton

300 million yen(Note 1) ー

300 million yen

600 million yen

Reduction of CO2 emissions

Reduction in waste discharge (land fill/incineration)

Selling recyclable materials (scrap, oil, etc.)

TotalNote 2: Reduction compared to the previous yearNote 3: Total quantity of recyclable materials sold for the year

Environmental Conservation Benefits

Mass (weight)

Regular A/T New A/T

32% less

Transmiss ion Ef f ic iency (4-speed, 60 km/h on a leve l road)

Regular A/T New A/T

＋5％％

Base

Sl ip Control

Throttle opening

Car speed

Lock-upOFF region

Lock-upON region

Slipcontrolregion

Regular ECU New ECU

61% less

Area

Regular ECU New ECU

60% less

Mass (weight)

Regular ECU New ECU

79% fewer

J i gs

Regular ECU New ECU

Ultra Smal l EV Drive System(used in the Toyota“e・com”) IPM motor

3-shaft reductioncounter gear

Diff gear

Structure of “Air Navi ,”a Photocata lyt icPur i f ier /Vent i lator

Photo-platinumcatalyst filter

Dirty inside air

Outside air

Heat exchanger

Electrostaticdust filter

Energy-saving Measures

Downscaling facilities

Improvingfacility utilization

Reducing the number of parts

Net shape

Shortening cycle times

Discontinuing or consolidatingmanufacturing processes

Shifting from hydraulic to servo controls

Technical ingenuity

A4-size crimping machine

Assembly lines for diverse models

Multi-purpose flexible lines and facilities

Integral molding of presses

Sintering

Cold forging

High-precision casting

High-speed processing

Reducing down time

Development of inexpensivemanufacturing techniques

Sharing of facilities

Module assembly

Assembly center

Energy-saving

From product development stage・Considering production factors as part of good product design・Developing manufacturing techniques

Production reform・Higher speed・More flexibility・Downscaling

Reducing thenumber of faciliti

Simplification offacility specifications

Large-scale special transfer machine⇒Multi-purpose line at High Speed Machining Center

Conventionalprocess

Developed�process

MachiningCenter

MachiningCenter

MachiningCenter

MachiningCenter

MachiningCenter

WashingTransfer machine

Concentrated coolant device

Transfer machine Pressure/leak test

Pressure/leak test

Washing Pressure/leak test

Pressure/leak test

Multi-purposemodule line

Raw materials

Raw materials

Impregnation

Impregnation

Developing Concrete Measures

◎=Very effective　◯=Effective　△=Not so effective

Changing machine tool materials

Optimizing cutting conditions

Reducing temperature of cutting edges

Improving materials that are cut

Improving machine tool materials

Improving swarf processing

Reducing wear of cutting tools*Improving the design of machine tool cutting edges

Carrying out vibration cutting

Increasing machine tool hardness

Adding coatings

Reducing feed rates

Reducing speed

Using higher coolant pressure

Making hardness structure more uniform

Eliminating blow holes

Increasing the toughness of machine tools

◯

◯

◎

◎

△

◎

◯

◯

◯

◯

Maintaining quality levels (accuracy)

*Reducing wear of cutting toolsExtending the life of cutting tools

Reducing chipping of cutting edgesMain points to implement

Effectiveness in Reducing Electric Power Consumption (target: 40 lines, including cutting tool polishing-related lines)

2,837

10,000 kW/year

1999 result 2000 result 2001 result

2,856

2,842

0.5% lower0.2%lower

Effectiveness in Reducing CO2 Emissions (calculated by power consumption)

5,064

0.2%lower

1999 result 2000 result 2001 result

tons/year5,098

5,073

0.5% lower

Returnable stee l pa l lets for sea fre ight

Non-returnable stee l pa l lets for sea fre ight

2001:427 units remanufactured

AW Europe Service Center

2001:16,114 units remanufactured

Service Center

2001:22,135 units remanufactured

AWTEC USA

T/C=Torque Converter

User Dealer AW Service CenterDisassemble,inspect andremanufacture

Partsrecycling

Installremanufactured A/T

Complaint Order

Inventory shipmentRemanufactured

Vehicle checkand diagnosis

Customer distribution center

Order

T/C remanufacturing

Partsreproduction

Process Out l ine

Total Number of Remanufacturing A/Ts

total units

y e a r

780,145

69 71 73 75 77 79 81 83 85 87 8988 989491 93 95 97 99 0001

Introduced returnablecontainers (Dec. ’99)

Started T/Cremanufacturing (April ’00)

Started remanufacturing A/Ts forTOYOTA models (’79 to ’89)

May’96 Commenced A/Tremanufacturing with thefounding of AW

Opened AWTEC USA(April ’88)

Opened AW EuropeService Center(July ’98)

Cogeneration system at head plant

Electricity（31） Electricity（36）

Electricity（5）

Warm water（17）

Boiler feedSteam drain

Steam（11）

Steam

（49 ）

Loss Loss

Exhaustheat

（69 ）

Steam

（44 ）

Steamturbine

Exhaustheat

boiler

Gasturbine

generatorCity gas

This is a system that utilizes waste heat from gas turbine generators for use as energy. This innovative system has earned a grant from NEDO (New Energy and Industrial Technology Development Organization) in recognition of its pacesetting technology.

Waste Reduction Plan

Landfilled Waste

Incinerated Waste

4,000

2,000

0

(Metric tons/year)

3,586215

3,371

2,850135

2,715

2,617

2,558

59 2,418

2,418 1,000

1,000169169

2000 2001 2002 2003 2004 (Year)2005

Zero Emission Campaign

Tour by top management

Zero Emission News

Red Card

Purchas ing Pol ic iesExplanat ion Meet ing

Environmenta lSa fety Checksat Suppl iers ’ Premises

Suppliers

Name Activity detai ls

All AISIN EnvironmentalProtection Study Group

●Reducing waste●Managing chemicals etc. 12

AW GroupEnvironmentalProtectionLiaison Association

●Environmental management●Promoting strict conformance to　 laws and regulations etc. 12

Purchasing PoliciesExplanation Meetingfor Suppliers

Environmental SafetyChecks at Suppliers’Premises

Members of the�Council of AW�Cooperating�Companies

●Explanation of AISIN AW　environmental policies●Environmental rules●Environmental protection activit ies etc.

39

175

●Explanation of AISIN AW　environmental policies●Environmental protection activit ies etc.

●Corrective measures for problems,　defects●Setting up emergency systems etc.

No. ofparticipatingcompanies

Aisin Seiki Co., Ltd.Aisin Takaoka Co., Ltd.

Aisin Chemical Co., Ltd.

Aisin Sales Co., Ltd.

Aisin Keikinzoku Co., Ltd.

Aisin Sinwa Co., Ltd.

Aisin Development Co., Ltd.

Aisin AW Co., Ltd.

Aisin AW Industries Co., Ltd.

Aisin Sin'ei Co., Ltd.

Aisin AI Co., Ltd.

Aisin Kiko Co., Ltd.

IMRA Japan Co., Ltd.

AW Engineering Co., Ltd.

AW Software Co., Ltd.

AW Service Co., Ltd.

AW Maintenance Co., Ltd.

Aisin AW Industries Co., Ltd.

Equos Research Co., Ltd.

Aisin AW Co., Ltd.

Cooperat ive Act iv i t ies

Newchemicals

Examine introduction ofnew chemicals

MSDS

Comprehensive evaluations

No problem

Problem

(Use is banned)

Preliminary checking

RegulationsBanned substances

Influence on human healthand the environment

Effect on human healthEffect on the environment

Effluent treatment test (Approved for use)

Preliminary Chemical Evaluation Systems

MSDS information

Total consumptionquantity

Total dischargequantity

Creation ofreport materials

Register withMSDS

Chemicals management system

Outline of Chemicals Management System

Input stochasticformula

Order materials(Ascertain consumption quantity)

Head Office

Rotary kiln incinerator Secondary incinerator Alkali wash cyclonescrubber

Decomposes dioxinby re-burning exhaustgases at over 800°C

Eliminates hydrogen chloride gas and otheracidic compounds

HCL

Dxn

700

10

18

2001

0.012

●Exhaust Gas Data

Units for HCL (hydrogen chloride) are mg/m3N; units for Dxn (dioxin) are ng-TEQ/m3N

Control l imit

Okazaki Plant

Fluidized-bed incinerator Bag f i lter dust collection

Adsorbs and eliminates acidic gases,hydrogen chloride gas and dioxin.

HCL

Dxn

700

5

40

2001

0.000067

●Exhaust Gas Data

Units for HCL (hydrogen chloride) are mg/m3N; units for Dxn (dioxin) are ng-TEQ/m3N

Decomposes dioxin by re-burningexhaust gases at over 800°C

Adds calcium hydroxideand activated carbon

Control l imit

m3/day

Domestic waste water

2,320

800

704Head Plant Okazaki Plant

310

Total 3,120 1,014

Industrial waste water

Water TreatmentCapacity of Our Plants

Denitrif ication tank Nitrif ication tankNo. 1

Nitrif ication tankNo. 2

Ultra f i l trat ion membrane (hol low f iber membrane)

BiologicalProcessing Flow

Okazaki Plant ComprehensiveWater Treatment Plant

Okazaki PlantRecycling Facility

Industrial waste water(recycling rate 20%)

Domestic waste water(recycling rate 40%)

Recycling rate =amount of recycled water

amount of treated waste waterx 100

Recycling Flow

Facility Toilets Water treatment plant

Industrialwater

Domestic wastewater

Industrial wastewater

Main Measuring Equipmentfor Manufacturing Processes

PH meter

DO meter

MLSS meter

TOC meter

COD meter

Turbid i ty meter

Tota l N meter

●

●

●

●

●

●

●

●

●

Discharge

●

●

●

●

●

CondensationTreatment

BiologicalTreatment

TertiaryTreatment

PHAdjustment

Energy Building(includes Central Monitoring Room)

Structure of Oil and WaterSeparation Tank Treatment Plant

P

TreatmentPlant

Minister for Internat iona l Trade andIndustry Award for the Greening ofIndustr ia l Fac i l i t ies

Chief of Agr icu l tura l Product ionBureau Award for the Nat iona l F lowerTown Creat ion Contest

Flower Festival ,(which al l employeestake part in)

Facil it ies or Events

Parks

Frequency

once a year

once a year

once a year

Details

Open to employees, their famil ies and local residents

All AISIN Charity Concert etc.

Work experience programs for local students etc.

Various events, a charity bazaar, and offers offree bonsai and foliage plants grown by our employees

Inter-company basketball league,community volleyball meets etc.

Community softball meet,Anjo City soccer league etc.

Indoor swimming pool

Harmony Hall

Production plant

Family Festival

Gymnasium

Sports f ield

Facil it iesother

than parksthroughout the year

throughoutthe year

throughoutthe year

Opening Facilities and Greening Activities to Local Communities

Fami ly Fest iva l

All AISIN Charity Concert

Zero Waste Campaign

Head Plant

Water Qual i ty

Measures Control Limits(incl. agreed limits)

Measured Levels

Max. Average

Hydrogen ion concentration (pH)

Biochemical Oxygen Demand (BOD)

Chemical Oxygen Demand (COD)

Suspended Solids (SS)

Oils

Phenols

Copper

Zinc

Soluble iron

Soluble manganese

Chromium

Fluorine

Total Colon bacil l i

Total Nitrogen

Total Phosphorus

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*1: Hydrogen ion concentrat ion is measured by the pH index; units for colon bac i l l i are units /ml . F igures for other i tems without units are in mg/ l .

*2 : ND (“not detected,” i .e . leve l i s be low that detectable by measur ing equipment)

*3: F igures in brackets are da i ly mean va lues .

Air Qual i ty

*1: Units : SOx in m3N/H; NOx in ppm; smoke and dust in g /m3N; hydrogen ch lor ide in mg/m3N; d ioxin in ng-TEQ/m3N

Faci l i ty Names Control Limits(incl. agreed limits)

Measured Levels

Max. Average

Items

Smal l s ing le-pass boi lers

Boi lers (cold

and hot water

generators)

Heat ing furnaces

Aluminum

melt ing

furnace

Inc inerator

Gas tarb ine generator

SOx

NOx

SOx

Smoke and dust

Smoke and dust

NOx

SOx

Smoke and dust

Dioxins

NOx

SOx

Smoke and dust

Hydrogen chlor ide

Dioxins

NOx

SOx

Smoke and dust

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Machinery & Equipment Department

Service Center

Water Qual i ty

*1: Hydrogen ion concentrat ion is measured by the pH index; units for colon bac i l l i are units /ml . F igures for other i tems without units are in mg/ l .*2 : Tota l for sept ic tanks : 160 persons , 35 m3/day

I tems Control Limits(incl. agreed limits)

Measured Levels

Max. Average

Hydrogen ion concentrat ion (pH)

Chemica l Oxygen Demand (COD)

Biochemica l Oxygen Demand (BOD)

Suspended Sol ids (SS)

Colon bac i l l i

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Water Qual i ty

*1: Hydrogen ion concentrat ion is measured by the pH index; units for colon bac i l l i are units /ml . F igures for other i tems without units are in mg/ l .*2 : ND (“not detected,” i .e . leve l i s be low that detectable by measur ing equipment)*3: Tota l for sept ic tanks : 75 persons , 16 m3/day

I tems Control Limits(incl. agreed limits)

Measured Levels

Max. Average

Hydrogen ion concentrat ion (pH)

Chemica l Oxygen Demand (COD)

Biochemica l Oxygen Demand (BOD)

Suspended Sol ids (SS)

Colon bac i l l i

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Okazaki Plant

Water Qual i ty

*1: Hydrogen ion concentrat ion is measured by the pH index; units for colon　　baci l l i are units /ml . F igures for other i tems without units are in mg/ l .*2 : ND (“not detected,” i .e . leve l i s be low that detectable by measur ing equipment)

I tems Control Limits( inc l . agreed l imits)

Measured Levels

Max. Average

Hydrogen ion concentrat ion (pH)

Biochemica l Oxygen Demand (BOD)

Chemica l Oxygen Demand (COD)

Suspended Sol ids (SS)

Oi ls

Phenols

Copper

Zinc

Soluble iron

Soluble manganese

Tota l Chromium

Fluor ine

Colon bac i l l i

Tota l Nitrogen

Tota l Phosphorus

Transparency

Negat ive ion surfactants (MBAS)

Dissolved oxygen (DO)

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２０ degrees min

０．５

７ min

Air Qual i ty

*1: Units : SOx in m3N/H; NOx in ppm; smoke and dust in g /m3N; hydrogen chlor ide in　　mg/m3N; d ioxin in ng-TEQ/m3N-

Fac i l i ty Names Control Limits( inc l . agreed l imits)

Measured Levels

Max. Average

Gas turbine generator

Smal l s ing le-pass boi ler

Heat ing furnace

Inc inerator

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I tems

NOx

SOx

Smoke and dust

NOx

SOx

Smoke and dust

Smoke and dust

NOx

SOx

Smoke and dust

Hydrogen chlor ide

Dioxin

Tahara Plant

Water Qual i ty

*1: Hydrogen ion concentrat ion is measured by the pH index; units for colon bac i l l i are units /ml . F igures for other i tems without units are in mg/ l .*2 : ND (“not detected,” i .e . leve l i s be low that detectable by measur ing equipment)*3: F igures in brackets are da i ly average va lues .

I tems Control Limits( inc l . agreed l imits)

Measured Levels

Max. Average

Hydrogen ion concentrat ion (pH)

Biochemica l Oxygen Demand (BOD)

Chemica l Oxygen Demand (COD)

Suspended Sol ids (SS)

Oi ls

Phenols

Copper

Zinc

Soluble iron

Soluble manganese

Tota l Chromium

Fluor ine

Colon bac i l l i

Tota l Nitrogen

Tota l Phosphorus

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Air Qual i ty

*1: Units : SOx in m3N/H; NOx in ppm; smoke and dust in g /m3N; hydrogen chlor ide in mg/m3N; d ioxin in ng-TEQ/m3N-*2: AIS IN AW's tota l SOx emiss ion control e f forts are focused sole ly on boi lers (ch i l led and hot water generators) . The control va lue for boi ler SOx emiss ions is 4 .706m3N/H. Measured maximum va lue was 0 .742m3N/H, and average va lue was 0 .664m3N/H.

Fac i l i ty Names Control Limits( inc l . agreed l imits)

Measured Levels

Max. Average

Steam boi ler

Boi ler�(ch i l led and� hot water generators)

Aluminummelt ing furnace

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I tems

NOx

SOx

Smoke and dust

NOx

SOx

Smoke and dust

NOx

SOx

Smoke and dust

Dioxin

Company Out l ine

Establ i shed

Capita l

CEO

Sales

Major products

No. of employees

Address

May 15, 1969

26.48 bil l ion yen

Takao Taniguchi

432.6 bil l ion yen (2001)

automatic transmissions, car navigation systems

8,300 ( June 2002)

10 Takane, Fuji i-cho, Anjo City, Aichi 444-1192 Japan Tel: +81-566-73-1111

AISIN AW Environment Symbol