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



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


Mid-Term Targets

Total emission ofPRTR-listed materials


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 FindingsISO 14001 Audit Findings




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 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


●Oil Spill Dril


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 Committee Chairman: Hiroki IwasaMember of the Board



Environmental Events and Activities with Local Community





Observations

0件

0件

0件





Observations

0件

0件

0件


Environmental Committee Chairman: Takaoki Tsuchiya Member of the Board



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



●Awareness Training for Waste Reduction


●Installation of Lighting Fixtures with Inverters

●Reduction of Sludge in Wastewater

●Thorough Waste Sorting


●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


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

environmental report 2003 - tokai rika · 2012-10-05 · systems that enable drivers to convey...

Documents