CSR REPORT 2015

Transcription

CSR REPORT 2015

Contents
■Toyota Auto Body Profile
2
■Top Message
5
■Corporate Principles
7
■Corporate Governance
7
■ Devel o pi n g Em pl o yees an d
C reati n g th e W o rk pl ace
17
■ So c i a l C o nt r i b ut i o ns
26
■Friendly to the Global Environment 29
■ Creat ing Ev e r-B e tte r C a rs
8
■ P r od u c t E n v i r on me n t
30
■M eeting Cus to m er Expecta tio n s 9
■ P r od u c t i on E n v i r on me n t
33
■Crea ting H ig h Q u a lity Ca r s
■ E n v i r on me n t al M an ag e me n t
35
15
Editorial policy
This fiscal year marked the 70th anniversary of our founding, and based on the gratitude which we owe to our
customers and the history of our company, we endeavored to express our thanks to our predecessors and business
partners, and to broadly publicize our corporate activities over the year.
Additionally, in order to convey our efforts more easily, our activities are featured in this CSR report. Readers who
are interested in finding out more can use the click icons to access detailed information.
All opinions or concerns about this report and our activities are welcome via the questionnaire survey on the last page.
Report scope and time period
Report scope:
Toyota Auto Body and consolidated subsidiaries
Reporting period: In principle, this report covers from April 2014 through March 2015; however, reporting is
extended beyond March 2015 for items where progress after this period occurred.
C a r s on t he cov e r
Alphard
(Re- design ed m o d el a v a ila ble
for sa le Ja nu a ry 2015）
Vellfire
( Re- d e s i g n e d m o d e l av ai l ab l e
f o r s al e J an u ar y 2 0 1 5 ）
Esquire
Wheelchair-accessible specifications
(Re-designed model available
for sale October 2014）
1
Overview
Company Name Toyota Auto Body Co., Ltd.
Volume of sales
Head Office
100,Kanayama Ichiriyama-cho,
Kariya City,Aichi Prefecture, Japan
Established
August 31, 1945
Representative
President, Takahiro Iwase
（Thousands of vehicles ）
1000
719
750
621
500
711
617
434
Invested Capital 10.371 billion yen
250
1,714.7 billion yen
(FY2014 consolidated)
Total Sales
Manufacturing
Facilities
0
120
1
9
1945
1955
1965
1975
1985
1995
2014 (FY)
2005
Head Office ／ Fujimatsu Plant、
Number of employees ( consolidated )
Inabe Plant、Yoshiwara Plant、
(Number of employees)
Kariya Plant、
20000
Kotobuki New Development Center
17500
15000
13400
11600
Company Outline
R e la t ed
Inf o r m a t io n
9100
10000
6900
4100
5000
Product Lineup
0
1000
900
1945
1955
1965
1975
1985
1995
2005
2014 (FY)
Main Products
The year when the first generation of each model was introduced is shown in [ ].
Minivans
Alphard
Vellfire
Estima
〔2002〕
〔2008〕
〔1990〕
Commercial / Commuter vehicles
Hiace
Coaster
〔1967〕
〔1969〕
Voxy
〔2001〕
〔1968〕
Side Lift-up Seat
Vehicle
〔1994〕
Esquire
〔2001〕
〔2014〕
SUV
Land Cruiser
200
〔1998〕
Sedan
Land Cruiser
70 van
Land Cruiser
70 pickup
Prius
〔1984〕
〔1984〕
〔2004〕
Special Purpose
Vehicles
Assisted mobility vehicles
Wheelchair-accessible
Vehicle(Rear Lift type)
Noah
Small EV
Wheelchair-accessible Well Carry
Freezer & Refrigerator
Vehicle(Rear Lift type) （Special Purpose
Vehicle
Friend-Matic Vehicle）
〔2001〕
〔2009〕
〔1971〕
COMS
〔2000〕
2
Main Business Sites
Production Bases
Development Bases
Head Office/Fujimatsu Plant
Development Center
100, Kanayama Ichiriyama-cho
Kariya City, Aichi Prefecture
Inside Head office / Fujimatsu Plant
Main Products
Estima、Voxy、Noah
Esquire、Prius
Land Cruiser 70
Inabe Plant
10, Ichinohara Inabe-cho Inabe City
Mie Prefecture
Production Technology
Center
Main Products
Alphard、vellfire
Hiace、Regius Ace
Inside Head office / Fujimatsu Plant
Yoshiwara Plant
25, Kamifujiike Yoshiwara-cho
Toyota City, Aichi Prefecture
Kotobuki
New Development Center
Main Products
Land Cluiser 200
Lexus LX570（Export model）
Land Cruiser 70
Coaster
1-36-1, Kotobuki-cho, Toyota City,
Aichi Prefecture
Kariya Plant
2-1, Showa-cho, Kariya City,
Aichi Prefecture
Main Products
COMS
Assisted mobility vehicles (Welcab)
Domestic and Overseas Consolidated Subsidiary Companies
Domestic Consolidated Subsidiary Companies
Gifu Auto Body Co., Ltd.
（Kakamigahara city, gifu Pref.）
〔1940〕
＜Manufacture and sales of automobiles
and automotive parts＞
Ace Industry Co., Ltd.
（Kariya City, Aichi Pref.）〔1974〕
＜Manufacture and sales of parts, equipment,
and other products＞
[ ] indicates the year when the company was founded.
＜＞ indicates the primary area of business.
Tokai Utility Motor Co., Ltd.
（Anjyo City, Aichi Pref.）〔1954〕
＜Manufacture and sales of
special purpose vehicles＞
Tokai Parts Industry Co., Ltd.
Toyota Body Seiko Co., Ltd.
（Takahama City Aichi Pref.）
〔1992〕
＜Manufacture and sales of seat
and other parts＞
TABMEC Co., Ltd.
＜Manufacture and sales of stamped
and sheet-metal parts＞
＜General maintenance of buildings
and associated equipment＞
3
Domestic Consolidated Subsidiary Companies
Toyota Auto Body R&D co., Ltd.
（Kirishima City, Kagoshima Pref.）
〔1990〕
＜Design and testing of automotive parts＞
Life Creation Co., Ltd
（Toyota City, Aichi Pref.）〔1993〕
＜Operation of off-road facilities＞
〔〕indicates the year when the company was founded.
＜＞indicates the primary area of business
Life Service & Security Corporation
（Kariya City, Aichi Pref.）
〔2000〕
＜Management of office and employee
recreational acilities, security agency work＞
Life Support Co., Ltd.
（Anjyo City, Aichi Pref.）〔1999〕
＜Sales of nursing care supplies,
home helper services＞
Overseas Consolidated Subsidiary Companies
PT.Sugity Creatives
（Indonesia）
〔1995〕
＜Manufacture and sales of vehicles
and resin parts＞
PT.Toyota Auto Body-Tokai
Extrusion
（Indonesia）
〔2005〕
＜Manufacture and sales of rubber
and resin molded parts＞
Toyota Auto Works Co., Ltd.
（Thailand）
〔1988〕
＜Manufacture and sales of vehicles＞
Chun Shyang Shin Yeh
Industry Co., Ltd.
（Republic of China (Taiwan)）
〔1997〕
＜Manufacture and sales of stamped and
sheet-metal parts, dies, and other products＞
Toyota Auto Body(Malaysia)
Sdn. Bhd.
（Malaysia）
〔2005〕
＜Manufacture and sales of stamped,
sheet-metal, and resin parts＞
PT.Resin Plating Technology
（Indonesia）
〔2013〕
＜Manufacture and sales of
resin plated parts and resin parts＞
Related Information
Inatec Co., Ltd.
（Inabe City, Mie Pref.）
〔2000〕
＜Environmental analysis and
measurement certification＞
GI Service Co., Ltd.
（Kakamigahara City, Gifu Pref.）
〔1988〕
＜Employee recreational, plant maintenance,
insurance and other services＞
＊A 100% wholly-owned subsidiary company
of Gifu Suto Body Co., Ltd., which is a
subsidiary company of Toyota Auto Body
Thai Auto Conversion Co., Ltd.
（Thailand）
〔2004〕
＜Manufacture and sales of special purpose
vehicles＞
Auto Parts Manufacturing
Mississippi Inc.
（U.S.A.）
〔2007〕
＜Manufacture and sales of stamped,
welded, and resin parts＞
Tab Minth Mobility Equipment
Co., Ltd.
（China）
〔2011〕
＜Sales of assistive devices＞
Overseas Subsidiary
4
■Top Message
Contributing to a Prosperous Society
by Creating Ever-Better Cars
I would like to express my thanks to everyone for their continuing
understanding and support.
Toyota Auto Body was founded as a specialized truck manufacturer in
1945, and since that time we have taken an integrated approach from
development to production in order to create vehicles that are always
ahead of their times. Examples include the Toyoace trucks that have
been described as Japan’s national vehicle, Toyota’s first global
vehicle the Land Cruiser, the Hiace van that was the first “one-box”
commercial minivan in Japan, and the Estima which triggered the
minivan boom.
The environment surrounding our business is undergoing large
changes including energy and resource problems, an aging society,
and diversifying values as globalization progresses. Toyota Auto Body
intends to face these issues directly and contribute to a prosperous
society by creating ever-better cars.
President
Takahiro Iwase
Towards Creating Ever-Better Cars
(1) Meeting customer expectations
As a manufacturer of complete commercial vehicles, minivans, and
SUVs, we aim to produce vehicles that exceed customers’
expectations. For this purpose, we are dedicated to vehicle
production that incorporates market needs, such as the ways our
products are used around the world, the level of quality demanded by
the customers, customer requests, and other market information.
The re-designed Alphard and Vellfire that were released in January
2015 were developed and produced based on our efforts to directly
listen to user opinions, and have been highly popular as a true
crystallization of customer needs. In order to provide mobility freedom
and happiness to all people, we are now working on development and
production of assisted mobility vehicles for elderly and disabled
persons, and also of the COMS single-occupant electric vehicle.
Demonstrating the features of the Voxy
wheelchair-accessible vehicle
(assisted mobility vehicles)
(2) Creating ever-better cars begins
with the development of human resources
The foundation of creating ever-better cars is our people. Through
personnel training programs and teamwork-building activities, we are
working to create healthy and vibrant workplaces so that all of our
employees can be active on the global stage as car-manufacturing
professionals.
8,000 employees participated in the all-company sports day, which
was held last September for the first time in 15 years. We intend to
continue holding this sports day as an event where all employees work
together to develop an active workplace spirit and feeling of unity.
All-company sports day with 8,000
employees
5
■Top Message
Towards Creating an Ever-Better Society
(1) Social contributions
We believe that in order to be a company which is needed by society,
earning the trust of local communities is important.
At Fure-Ai Park (Fureai: interaction, Fureru: Touch and feel, Ai: love)
located adjacent to the Head Office Plant that opened in May of last
year, we host a rice-farming experience in which local elementary
school students participate, as well as environmental workshops and
other activities to improve communication with the community. We
intend to continue utilizing this park as an opportunity for community
interaction in the future.
(2) Environmental preservation
Preservation of the Earth’s environment is an important issue for the
creation of a sustainable society. We have formulated the Toyota Auto
Body Environmental Action Plan, and have set targets for each
process from design to production.
Specifically, in product development we are working to develop
weight-reducing technologies that will contribute to improved fuel
economy, and for product designs that maximize recycling. At our
plants, we are working to reduce CO 2 emissions, including the
installation of the latest cogeneration systems.
Weaving ceremonial ropes
using rice
straw from the
rice field
Students experiencing rice
farming at Fure-Ai Park
Building a
low-carbon
society
Building a
recycling-oriented
society
Fifth Toyota Auto Body
Environmental Action Plan
Environmental preservation
and building a society that is
in harmony with nature
Environmental management
Gratitude for 70 Years of Progress
This year in August, Toyota Auto Body will celebrate the 70th anniversary of our founding.
We are profoundly grateful to the customers who have bought and used our products and
made this success possible. We would also like to sincerely thank the members of the local
communities, everyone at our suppliers and affiliated companies, and our predecessors who
built our company’s history.
In this milestone year, everyone in the Toyota Auto Body Group will work together to make
us a business group that is even more needed by people in our society. For this purpose, I
would like to ask for everyone’s continued support and guidance.
June 2015
＜70 years of progress＞
【Founded in 1945】
Toyoace
（1954）
Land Cruiser
（BJ Series）
（1953）
Hiace
（1967）
Estima
（1990）
6
■Corporate Principles
Toyota Auto Body conducts business based on the company motto and fundamental principles
which carry on the Five Main Principles of Toyoda (formerly known as the Toyoda Precepts),
focusing on all stakeholders in order to contribute to the development of a sustainable society.
Toyoda Precepts
Company Motto
（Created in 1963）
(Created in 1935)
1. Be contributive to the development and
welfare of the country by working
together, regardless of position, in
faithfully fulfilling your duties;
2. Be at the vanguard of the times through
endless creativity, inquisitiveness and
pursuit of improvement;
3. Be practical and avoid frivolity;
4. Be kind and generous, strive to create a
warm, homelike atmosphere; and
5. Be reverent, and show gratitude for
things great and small in thought and
deed
Fundamental Principles
(Created in 1995, revised in 2004)
Toyota Auto Body stands with the global view
for research and manufacturing while
contributing to society with our fine products
to have unceasing advancement of business
practices
1. Having harmonization with environment and
open and fair corporate ethics as our
foundation, our goal is to contribute to building
a prosperous society as a trusted company in
international community.
Development:
2. Placing customer as our priority first, provide
“quality products”to enrich their life space by
research and creations.
Stay ahead of current trend and respect
ideas and time
3. Invigorate employees and organization to
develop our company culture with creativity and
vitality to pursue company prosperity as well as
happiness our employees.
Amity:
Encourage honesty and cooperation with
sincerity and faith
Appreciation:
4. By building business relationships based on
mutual trust, strengthen management practices
with each other, and create long-term growth
and prosperous coexistence.
Reflection should be the nourishment for
the enterprising sprit, and live for the joy of
diligent labor
「CSR Policy」
■Corporate Governance
In addition to greater efficiency, at the same time we are also working for mechanisms
that ensure highly transparent management.
The Executive Member System was introduced to
define the roles of our board of directors and corporate
officers. The board of directors is responsible for
executive decisions and supervisory functions, and the
corporate officers are responsible for business and
corporate affairs. Our intention is to ensure quick
decision-making for our business development strategy
and to speed up our operations by reducing the
number of directors.
We have also created a system for cross-divisional
committee deliberations related to business and
corporate affairs.
Additionally, the Audit Department for all divisions at
Toyota Auto Body performs internal audits centering on
the areas of compliance and reliable financial reporting.
In addition, we also carry out audits which include
external auditors, as well as accounting audits by
accounting auditors.
Toyota Auto Body Corporate Governance
Shareholder’s Meeting
Appointment and Oversight
Audit
Auditors
Accounting
Auditors
Coordination
Report
Board of
Directors
- CSR Committee
Report - Corporate Ethics Committee
Accounting
Audit
Audit
Department
Internal Audit
Corporate
Officers
Guidance
- Product Environment
Committee
- Production Environment
Committee
- Social Contribution
Committee
- BCM Committee
- Central Safety and Health
Committee
- Disaster-prevention
Committee, etc.
Report
Individual divisions
In order to improve our activities related to corporate ethics, compliance, risk management, social contributions, and the
environment, we established the CSR Committee, which is comprised of all board directors and auditors. We also established
four committees below the CSR Committee in May of 2009 for deliberating and taking action on important issues.
7
■Creating Ever-Better Cars
Providing smiles to our customers
through“Creating Ever-Better Cars”
Development Management Headquarters
Hiroshi Ohashi,
Executive Vice President
As we develop products at Toyota Auto Body, we imagine the smiling
faces of our customers as we look to exceed expectations and deliver
happiness and excitement.
In order to do so, our technical development engineers travel not only
in Japan but around the world to see with their own eyes and listen to
the customers, and to determine how our vehicles are actually used in
the markets as they carry out development.
Fundamental Thinking for Our Efforts
1. Sincerely listen to the voice of our customer, and
deliver products that surpass their expectations
and requests from customer’s point of view.
2. Provide balanced products with design,
marketability, performance, quality and safety.
Our customers’
smiling faces
Styling
Safety
Usability
Environmental Quality
performance
Marketability
Durability
Placement Product Development
Toyota Auto Body is a complete vehicle
manufacturer that is involved in the overall process
from design to development, and our development
headquarters has unified ourselves to work on
“Creating Ever-Better Cars.”
Creating Ever-Better Cars
Meeting the expectations of our customers
Development (planning, image design, technical design)
Product planning
From
development
to quality
assurance
Investigating how
customers use our
products and customer
requests
Image design
Imaginative designs
Technical design
High-quality designs
Creating high-quality
cars that provide safety and security
Safety
Quality
Testing and evaluation
Quality assurance
Actual vehicles are produced
to confirm safety performance
(E.g: Collision testing)
Delivering high quality to
customers by making
processes easier to perform
(E.g.: Molded headlining
installation)
Customer evaluations:
Positively evaluated at IQS
(Initial Quality Surveys)
conducted in the US and
Japan by J.D. Power.
Creating plans based on
market investigations
Making models that
express the design
image
Using CAE to achieve
both stylishness and
performance
Performance verification
using actual vehicles based
on predicted usage and
environmental conditions
(E.g.: Snow road testing)
8
Meeting Customer Expectations
Aiming to Create Cars that Exceed Customer Expectations
We place great value on our customers’opinions, and we carry out product development
aiming to create ever-better cars that exceed the customers’expectations.
(The re-designed Alphard and Vellfire were launched in January 2015.)
Working to Satisfy Every Customer
When developing the re-designed Alphard and Vellfire, we
aimed to create better cars that exceed expectations by
focusing on families with children, and by listening not only to
the needs of drivers, but also of the children, elderly persons,
and others who occupy the back seats.
Making best use of our customers’valuable opinions and feedback
In response to the many different
opinions that we receive from
customers, our development engineers
travel to the markets themselves to
observe how the cars are actually used
and listen directly to the customers.
＜Feedback from customers:＞
・Nice, large interior
・The wide range of rear seat arrangements
makes for improved comfort.
・Good stylish design
・Visibility and field of view from the driver’s
seat are excellent.
・More comfortable
・More storage space would be nice.
・A higher-grade interior would be better.
・It should be easier to get into and out of the car.
・A wider front passenger seat would be a
good idea.
Checking customer preferences and
trends regarding the feeling of front
seat visibility
To exceed customer expectations
From the opinions we receive, we strive to identify what the customers truly want, and
incorporate the results into our ideas. The ideas born from customer opinions are
reproduced in the interior models. With the cooperation of company staff users and others,
repeated verification is carried out as the product is created.
Comment by an Alphard and
Vellfire developer
Product Planning
Center
Teruji Kuroyanagi
There was a lot that we
gained from customer
opinions and observing how
the cars were actually used
in the market. I could
clearly feel the importance of
the customer's perspective.
Verifying the user-friendliness of the
front passenger long sliding seat
Verifying the ease of getting into and out
of the car after lowering the step height
9
Responding to the request for minivan comfort on the same level as a luxury car
A new double-wishbone rear suspension was developed together with
Toyota, achieved without harming the balance of a low floor and optimal
seat layout. Increasing the number of spot welds and using the same
structural adhesive that is used in luxury cars helped to increase body
rigidity and improve riding comfort.
Increased number of spot welds
Use of adhesive
New rear double-wishbone suspension together
with a low floor and optimal seat layout
Improved riding comfort resulting from higher body rigidity
Responding to requests for further style improvements
Aiming to further improve on the popular design
A-pillar
of the previous models, we adopted a package
moved forward
that provides a stately shape and curvy surface
configuration.
Higher
hood height
Reduced
overall height
Larger
door panel
Lower door
bottom edge
Old model
Larger total length
and wheel base
New model
Larger total width
and tread
Responding to requests for a wide and comfortable front seat as well as rear seats
The seat rails were connected from front to
rear, increasing the front passenger seat
movement range. This produces a seat
arrangement where the front passenger seat
can also be comfortably used in a wide
range of configurations.
Seat sliding distance
Max. 1160 mm
Front passenger super long sliding seat
Sample arrangement
Responding to requests for easier entry and exit
So that people can more easily get into
and out of the car, a lower and wider
step was installed. A long assist grip
was also adopted so that it can be
gripped easily by small children. In
addition, the door opening was
widened for even easier entry and exit.
Step width:
+30 mm compared
with previous model
Step height:
-50 mm compared
with previous model
A lower and wider step
Grip length
485mm
Long assist grip
Door opening width:
+70 mm compared with
previous model
A wider door opening
Even greater appeal of the re-designed Alphard and Vellfire
10
For the Safety of Our Customers
We are pursuing safety from the two directions of helping to prevent accidents with active
safety technology and reducing damage in the event of a collision with passive safety
technology in order to continue providing safe and dependable cars to the customers.
Strengthening Safety Functions for Helping to Prevent Accidents (Active Safety)
The re-designed Alphard and Vellfire support the driver and help ensure safety with vehicle periphery sensors
and automatic brake control.
When the car is stopped in a parking lot or elsewhere, objects that are difficult for
the driver to see are displayed on a monitor.
The panoramic view monitor allows the
driver to check the conditions all around
the vehicle from the driver’s seat.
The see-through view function displays
the view with a transparent vehicle body.
View from outside the car
Not visible from the driver’s seat
During expressway driving, a system tracks the car ahead
and smoothly brings the car to a stop
The radar cruise control (with all-speed tracking function) can maintain
a suitable following distance behind the car ahead in a wide speed
range from 0 to 100 km/h.
When the car ahead stops, the system brings the car to a stop while
keeping a suitable distance from the car ahead.
Can be seen on the monitor.
No car ahead:
Car ahead:
Drives at
the set speed
Tracks the car
ahead in the
range from the
set speed to
stopped
Stopped
Improving Safety in Various Situations (Passive Safety)
Achieving both collision safety and lighter weight
A high-strength cabin is used to
protect the passenger space in the
event of a collision, and at the same
time expanded use of high-tension
steel sheet reduces the vehicle weight.
In particular, 980 MPa grade and
higher high-tension steel sheet is
positioned optimally as the structural
members
Comment from a collision safety
evaluation team member
Collision Safety Test Dept.
1500MPa grade
Reducing injuries to pedestrians
Shinichi Yamaguchi
980MPa grade
590MPa grade
We completed development
of a lightweight and
high-strength body.
We are confident that we
can deliver safety and
security to customers.
440MPa grade
Mitigating impact to the head
An impact-absorbing structure is
used on the hood, bumper, and
other parts in order to mitigate the
impact on the pedestrian in the
event of a collision.
Mitigating impact to
pedestrian legs
The moment when a head
dummy strikes the hood
The slits on the inside of the hood
deform to absorb the impact
Results of Programs for Creating Safe Vehicles
11
Developing more Customer-Friendly Commercial Vehicles and SUVs
We are working on developing the most suitable products by monitoring and analyzing how our vehicles
are used in countries and regions around the world using the genchi-genbutsu (going to see the actual
site and actual object) approach in consideration of the customers’tastes and conditions of usage.
Incorporating the Ways Customers Use our Products around the World to Product Development
Responding to requests for Hiace improvements
Changing to a sliding front passenger seat
The Hiace is broadly popular both in Japan and overseas. In
order to meet the expectations of customers, we investigated
actual vehicles in the local markets, strengthened our means of
rapidly acquiring customer information, and took other steps to
identify the ways the vehicles are used and requests for
improvements in great detail so that we could apply them to
product development.
120 mm slide
Australia investigation: In response to numerous comments
that the front passenger seat does not have enough leg
room, we adopted a sliding passenger seat.
（From Dec. 2014）
Responding to requests from many Land Cruiser 70 fans
To commemorate its 30th anniversary, we have re-introduced
the Land Cruiser 70 in Japan for the first time in 10 years.
In active service around the world, the Land Cruiser 70 also has a
large fan base in Japan. In response to their requests, we resumed
sales of the Land Cruiser 70 for a limited one-year period.
(Vehicles will be produced up to the end of June 2015.)
To meet the needs of users worldwide, in addition to compliance with
the latest laws and regulations, we have also carried out development
aimed at improving safety.
Semi-long van
Double-cab pickup
Responding to requests for Coaster improvements
Development of new Coaster rear seats
In response to customer requests obtained from
local investigations in Australia, we developed
large-size seats with an extra margin of space.
We will continue to carry out product development
that is tailored to satisfy customers’intended
requirements.
Seat back height:
+273 mm compared
with previous model
Rear seat for Australia
(Figure shows 2-person seat)
From Jan. 2015
Investigation in Papua New Guinea:
Many Coasters transporting passengers at a bus terminal
Comment from a local investigator
TOPICS
Product Planning Center
Dakar Rally 2015 We finished first and second in the Cross-Country
Series Production Vehicles class with the same vehicle that our
worldwide customers are driving! (2nd consecutive victory)
Finished first and second in the
Cross-Country Series Production
Vehicles class!
The Dakar Rally is another opportunity to prove
the reliability and off-road performance of the
Land Cruiser.
Dakar Rally HP
Hisashi Takemoto
Our products are used as
means of transportation by
customers around the world.
We will continue making
advances to meet customer
expectations not only by
increasing durability, but also
by further improving safety
systems and comfort.
In this race, we use eco-friendly 100% biodiesel fuel
that is refined from used cooking oil provided by
people in areas nearby our company.
12
Producing Cars to Meet the Needs of a Diverse
Range of Customers Around the World
We are developing assisted mobility vehicles that can be enjoyed by disabled persons, as
well as by elderly persons, nursing caregivers, and family members, and are also developing
and providing a wide range of special purpose vehicles that are built to meet market needs.
Assisted mobility vehicles: Providing Freedom of Mobility and Joy to Everyone
In order to satisfy our customers, we visited nursing care
facilities and facilities for the elderly to see how our products
are actually used and to acquire user opinions ‒ information
which we apply to product development.
Investigating how our products are used at nursing care
facilities and facilities for the elderly
We are also actively carrying out activities in Japan and
overseas so that more people know about these vehicles.
Lineup of Assisted Mobility Vehicles and Equipment
Comment from a team member in charge of marketing for China
Conversion & Mobility Vehicle Center
Hirotsugu Okuya
Assistance by nursing caregivers
and facility staff
Elderly persons and caregivers
on the same platform
Japanese and overseas promotion activities
It is expected that the number of elderly
people in China will exceed 500 million in
2020. In cooperation with Toyota, we are
carrying out activities aimed at expanding
the use of assisted mobility vehicles, and
are working to contribute to this field in
China based on the freedom of mobility
concept.
Activities in China (TAMI)
Special Purpose Vehicles: Supporting Everyday Living
Our subsidiary Tokai Utility Motor Co., Ltd. develops and
manufactures utility vehicles to meet a broad range of needs.
Using a real vehicle to explain the
characteristics of assisted mobility
products to customers
(Barrier-free exhibition in Japan)
Introducing assisted mobility
vehicles to customers in China
(China International Exhibition
of Rehabilitation, Nursing &
Healthcare)
Mobile sales vehicles that played an important role at
temporary housing facilities following the Great East
Japan Earthquake
Among the diverse lineup of products, the mobile sales
vehicles helped to support the lives of persons affected by the
Great East Japan Earthquake.
Lineup of Special Purpose Vehicle Equipment
For Full and Happy Living
We want people to enjoy happiness and excitement during
their everyday lives, and propose ideas for vehicles that can
be used for multiple purposes from commuting to leisure.
(Tokai Utility Motor Co., Ltd.)
Visiting a temporary housing facility
on high ground in Ofunato City
Full product shelves inside
the vehicle
Exhibiting and introducing actual vehicles in different areas
Activities of Tokai Utility Motor Co., Ltd.
Noah Tokimeki (excitement)
(Friendly Festa)
Esquire Tokimeki (excitement)
(Nagoya Camping Car Fair)
13
Preparing for a New Kind of Automotive Society
We are working to develop and produce the core components for Toyota’s fuel cell vehicles
that are leading the way to a hydrogen society. Aiming to achieve a low-carbon society
utilizing COMS, we have begun verification testing both in Japan and overseas.
Creating the Ultimate Eco-Car
Development and production of the core components for fuel cells
The world’s first 3D fine-mesh flow field that was developed by our
company is a core component in the fuel cell stack of the Mirai fuel
cell vehicle that was marketed by Toyota.
This flow field structure simultaneously improves both drainage
performance and air diffusibility, and achieves even power generation
across the cell surfaces. This yields a more compact size and higher
performance, with 2.2 times the output of previous products. We are
also producing components developed using the original
ultra-precise stamping technology that was developed by Toyota
Auto Body.
Comment from a developer of fuel cell core components
New Business Development Div. Naoki Yoshioka
By further improving the power
generation efficiency and productivity
of our 3D fine-mesh flow field, we are
working to improve the performance
of next-generation fuel cell vehicles
and contribute to their wider use.
Toyota Mirai fuel cell vehicle
Fuel cell stack
3D fine-mesh flow field (magnified view)
(Image provided by Toyota Motor Corporation)
Creating a New Society that Uses COMS
Verification testing in Japan
Hanamoyu Taiga Drama Hall
COMS are being used in
verification testing in many
regions with the goal of creating a
low-carbon society.
The use of COMS is also being
studied as a means of
transportation to sightseeing
spots located around Hagi City.
Use of COMS for movement to
historical sites and sightseeing
spots around Hagi City
Kasayama view
platform
★
Roadside Station
(Hagi Seaside Market)
★
Hanamoyu promotion specifications
Rental COMS
Hagi Castle Ruins
★
Shoin Shrine
Taiga Drama Hall
Shinkansen
(Shin-Yamaguchi
Station)
★
★
Shuttle bus
Tokoji Temple
★ ★
★
★
Home
Birthplace and Grave
of Shoin Yoshida
Former Taro Katsura Residence/
Former Yukawa Clan Residence
Verification testing overseas
In Grenoble, France the Cité lib by Ha:mo*
verification testing program for car sharing using
an ultra compact Toyota Motor EV was started
in early October 2014 using 35 COMS.
※ Joint project by Cité lib which operates the
sharing business, Électricité de France (EDF)
which constructs the charging infrastructure,
Grenoble City, and Toyota Motor
Grenoble, France (verification testing using i-Road and 35 COMS vehicles)
The Path of COMS
14
Creating High Quality Cars
Delivering High Quality Products by Putting the Customer First
Quality is created by coordination among development, production engineering, production,
and our suppliers. All Toyota Auto Body employees share and practice the Customer First
and Quality First ideals with a high level of kaizen spirit. In the future, we will continue to
coordinate among all areas as we work to further improve customer security and satisfaction.
Putting Customer First into Practice Throughout the Company
To set the Customer First and Quality First ideals deeply into the Message from the president
minds of all of our employees, we regularly conduct quality
lectures and exhibit quality case studies, and provide multi-level
quality training. In FY 2014, in addition to the above, we also
collected letters of thanks from the customers regarding high
quality car production, and sent them to all employees each
month so that each employee could understand the importance of
the Customer First ideal and apply it in his or her everyday work.
Exhibit of quality case studies
Delivering High Quality to Our Customers
High quality car production that extends
to the development phase
With the re-designed Alphard and Vellfire, coordination covers
all stages from the development phase to production
engineering, production, and our suppliers, as we worked for
improvements focused on simplifying production.
Participants earnestly studying
the case studies
Delivering high quality to our customers (re-designed Alphard)
Previously:
Now
Molded
headlining
The curtain shield airbag was installed in the
ceiling by a worker facing upwards.
⇒The work posture was bad, and there was
the risk of installation errors.
The curtain shield airbag is integrated
with the interior molded headlining, and is
inserted automatically.
Work is now possible from outside
the vehicle, making it more
comfortable and ensuring quality.
Deciding procedures and creating high-quality standards for work
On the production floor and in our offices as well, we have
introduced JiKotei-Kanketsu (JKK) activities (to take full
responsibility for your work and processes to prevent
problems being passed on to the next process) to achieve
quality improvements by striving to never inconvenience
the customer (i.e., the downstream process), and being
able to judge the results of your own work.
Specifically, this means continuing kaizen improvements by
organizing and carrying out each task from the viewpoints
shown below.
①First, identify the target and objective of the task.
②Identify the detailed procedure for the task.
③Identify the ryohin jyoken (quality points).
④Carry out the task. Immediately contact your supervisor
if a problem and/or delay may occur (pull the andon
cord) and carry out repeated kaizen improvements.
Group discussion of
JiKotei-Kanketsu themes
Studying improvements to work
methods in small groups
Division internal JiKotei-Kanketsu
presentations
Examples of department activities
are exhibited, and good ideas are
shared and put into practice.
「 Examples of Quality Programs: (Activities for simplifying vehicle
mass production, EDER activities, customer evaluations)
15
Creating High Quality Cars
Working for Ever-Better Cars Production Together with our Suppliers
We are engaged in purchasing activities that are based on open and fair transactions,
aiming for co-prosperity based on relationships of mutual trust with our suppliers, as
we work to create ever-better cars.
Basic Approach to Purchasing
For this purpose, we have established a Basic Purchasing Policy and
engage in global purchasing activities that aim to achieve the Customer First
ideal in partnership with our suppliers.
Aiming to Create Ever-Better Cars
New ideas for product development and manufacturing
in conjunction with all members of the supply chain
When the time for a model change approaches,
in addition to creating a wide range of bidding
opportunities, we also hold part workshops so
that suppliers can examine the parts and
understand our work on creating cars. In
cooperation between Toyota Auto Body and all
members of the supply chain, we are carrying out
activities to develop new ideas for creating
ever-better cars.
Creating
Ever-Better Cars
Strengthening
planning and
development
capabilities
Toyota
Auto
Body
Suppliers
We provide open and fair bidding opportunities to all suppliers in Japan and
overseas that would like to do business with Toyota Auto Body, regardless
of their nationality, size, or lack of previous transactions.
Production
innovations
Expansion
of overseas
business
Policy
Joint
related New product
development
activities exhibitions explanation
meetings and study groups
Basic
Open
Promoting
Mutual
policy
localization
and fair
trust
Towards creating ever-better cars
Design
PE
Toyota Auto
Plants
Body
Suppliers
Purchasing
Creating ever-better cars by centralizing the four key areas
(Cross-functional development operations)
Part workshops for both 1st-tier
and 2nd-tier suppliers
Sharing information with suppliers
We hold the Purchasing Policy Presentation Meeting in March of
each year in order to share our company’s annual purchasing
activities policy with the suppliers.
To make clear what we expect from our suppliers, we have created
and implemented the Supplier CSR Guidelines and Green
Purchasing Guidelines.
Programs that Support Purchasing Activities
Supplier exhibition
Educational activities using study meetings
with supplier participation
We are conducting education activities with a wide range of study
meetings conducted through the Shatai Kyowakai, a cooperative
meeting of suppliers. These include research meetings,
exhibitions, and the Transport Study Meeting and Safety and
Health Liaison Meeting that are intended to eliminate accidents.
Applying the results from supplier questionnaire
surveys to our purchasing activities
In order to further reinforce our system of open and fair
transactions and relationships of mutual trust, we ask
approximately 370 suppliers to evaluate our company’s
purchasing activities, and obtain opinions and requests that are
applied to future purchasing activities.
Mutually sharpening our skills
at the Transport Study Meeting
16
■Developing Employees and Creating the Workplace
Developing Employees and Creating a
Workplace for Creating Ever-Better Cars
Corporate Management Headquarters
Shinobu Ichikawa,
In order for Toyota Auto Body to provide ever-better cars that will deliver
happiness and satisfaction to our customers, we consider it important for each
and every employee to grow continuously, doing spirited work in a vibrant,
easy-to-work environment.
In“Our Priorities”, we have collected those qualities which we have inherited
from our predecessors and which we believe must be carefully preserved in our
work. By understanding the spirit of these qualities and putting them into
practice, we are working to develop an awareness of them through our work.
Workplace Culture and Mindset Innovation
Activities for Absorption and Establishment of“Our Priorities”
In order to deepen our spiritual understanding of what is important to us, we use a daily action declaration and
e-learning, and are carrying out activities to make this understanding a permanent part of our work. Similar activities
are carried out at our subsidiary companies in Japan and overseas.
【Ｂasic MAP：Our Priorities 】
Customer First
Click“Our Priorities”
(Revision issued
December, 2012)
We provide products and services that deliver
happiness and satisfaction through monozukuri
(manufacturing) to our customers, who we
consider first in taking action.
1.Customer First
■Everything Serves Customer satisfaction
■Completing Your Own Process Role
2.Challenge(P)
■Benchmarks ■Challenges
3.Execute(D)
１
■Being Aware of Your Own Role
■Achieve Your Duty Speedily
Customer First
Work Processes
4.Genchi Genbutsu(C)
We always set our targets one rank higher
and challenge new issues by ourselves
without feeling satisfied with current
conditions.
The work process PDCA Cycle
(Plan-Do-Check-Action) is essential for
achieving our targets.
２
Personnel development and
teamwork, the base of the
individual and the organization,
are made solid.
Challenge
５
(P)
Kaizen
(A)
４
5.Kaizen(A)
３
Execute
(D)
Genchi
Genbutsu
An Energetic Workplace
We create a safe and healthy
workplace in which all employees
are happy.
■Monitoring by Genchi Genbutsu
(On-site, hands-on experience)
■Repeating“Why?”Five Times
Personnel
Development
7.Teamwork
７
８
6.Personnel Development
■Personnel Training ■Self-development
(C)
６
■Continuous Efforts for Kaizen
■Learning From Mistakes
Teamwork
A Safe and Healthy Workplace
■Cooperation and Awareness of Roles
■Honesty and BAD NEWS First
■Willingness to Listen
8.A Safe and Healthy Workplace
■Safety Consciousness
■Follow the Rules
■Moral Consciousness
Overseas activities:
An original poster
has been created
and posted by Auto
Parts Manufacturing
Mississippi (USA).
Toyota Auto Body
Malaysia conducting a
managerial class study
session using the
English version of these
materials (Malaysia)
17
Developing Self-Sustaining Employees with Positive
Sprit to Challenge in Their Global Enfeavors
We at Toyota Auto Body are making continuous efforts toward “self-sustaining employees” , who are
capable of thinking and acting independently. We have constructed a human resource education
system from perspectives of the mid-to long-term. In addition, in looking toward new growth, we are
making efforts to enhance on the education of professional personnel capable of being active globally.
System for Promoting Individual Growth and Support for Employees
At Toyota Auto Body, we focus on educating
Skill development
with“Career Support Program”which is
Stratified
education
P
Provide the
opportunity
to study
S
spirit. We are promoting individual development
〔Career Support Program〕
A system to support education for
individuals by unified efforts of our
company, the supervisor(s), and
self. We are planning to our
education from the perspectives of
short-, mid-, and long-term
comprising educational planning,
standards, and measures.
Specialized training
single employee to have the vision and goal for
the future, and sufficiently work with positive
self-sustaining
employees
(Off-JT)
“self-sustaining employees”that allows every
Rotation
C
Fundamental Approaches to
Human Resource Development
designed to support employee development
MBO
accordingly to their plans.
OJT
Work experience
Training Professional Personnel
Employed and
entering company
Growth
through one’s work
Technical Development of Professional Personnel
Our training of engineers involves lecture rooms,
educational exhibits, and CAD training rooms so that
our engineers can learn through experience by
genchi genbutsu (going to see the actual site and
Development Engineer Training System (Step-climbing training table)
Entry-level employees
Beginner-level engineers
(years 1 to 3)
Intermediate-level engineers
(years 4 to 8)
Improve sense and
sensitivities of managers.
Manager training
actual object) and can make best use of their skills.
First-year new employee training is followed by
workplace OJT and third-year beginner-level training.
Beginning from the fifth year, intermediate-level
training and manager training for group leaders is
carried out. The use of this step-up training aims to
further strengthen development abilities.
Training involving use of on-site
work for entry-level employees
Intermediate-level
training
Advance from part engineers
to vehicle developers.
Become
independent
after 3 years.
Beginner-level
training
New employee
training
New employee CAD* training
* CAD：Computer Aided Design
Manager
1. Study from group leader handbook
(At time of new posting)
2. Learning through reflecting on past actions
--- others
1. Vibration & noise
2. Collision safety
3. Human engineering
--- others
1. Design information system (beginner)
2. Steel sheet and resin material engineering
--- others
Learning special skills in
intermediate-level training
Training of new group leaders
Production engineering professionals
Engineering training was started in 2008, aiming to create the
world’s top level of minivans, commercial vehicles, and SUVs.
During the first year, trainees undergo basic engineering
training through vehicle disassembly training and genchi
genbutsu training. In the second and later years, they
undergo OJT with their mentors. The mid-level employees
learn high-level production engineering at the Engineer
School.
Training, presentations, and other programs are also carried
out at key milestones, as we work to strengthen production
engineering abilities on a daily basis.
Vehicle disassembly training
for entry-level employees
Presentations given in
employees’second year
18
Production professionals
improve our abilities.
Intermediate-level
engineers
refining and transferring skills, aiming to further
―
Working + thinking
+ evaluating + improving
Grade 3
Grade 1
Grade 2
Entry-level
engineers
Grade 1
Working + thinking
+ evaluating
Working + thinking
Upper-level
Grade 3
Intermediate-level
Grade 1
Intermediate-level
Grade 2
Entry-level
engineers
QC circle activities
customers. We also actively carry out programs for
Working + thinking + evaluating
+ improving + instructing
―
Company-wide skills competition
staff in order to gain the confidence and trust of the
Upper-level
engineers
We conduct education and training for engineering
Production engineer training system (step-up training diagram)
Legend
: Require skill levels (guidelines)
Grade 2
→Years of experience
Educating new employees
Before employees are assigned to a workplace, they undergo
basic knowledge training and basic skills training that are
conducted by full-time trainers.
Basic skills training for
new employees:
National Skill Olympics:
We are also challenging ourselves to enter the National Skill
Olympics as a way to rapidly train the personnel who will
become the future workplace leaders.
Mid-level employee training
Practical training and knowledge-based training are carried out
according to the employees’qualifications in each job type:
stamping, body work, painting, molding, assembly, logistics,
and maintenance.
Training conducted by full-time trainers
Fighting-Spirit Award Winner
(Automotive Sheet-Metal Working Compettion)
Jin Tanaka
Company-wide skills competition:
Refining skills
The company-wide skills competition is a large opportunity for
refining skills. Employees from subsidiary companies in Japan
and overseas also participate in this competition, with the
members of the Toyota Auto Body Group competing with one
another as they aim for skill improvements.
Training professionals for overseas production
We are also working to train local engineering staff of overseas
subsidiaries. Japanese engineering trainers are sent to conduct
local training, and local trainers receive training in Japan.
Improving Local Capabilities
and Teamwork
Body work
Painting
Overseas personnel training:
Training in Japan
Training by instructors sent overseas
We are working on strengthening our workplace
capabilities to create workplaces where employees are
able to resolve issues through strong teamwork.
QC circle activities
All Japan QC Circle Conference:
526 circles including those from subsidiaries in Japan and
overseas participate in these activities as an opportunity to learn
and grow together. At the Toyota Auto Body Group QC Circle
Competition, selected circles deliver presentations that are
intended to further raise the level of these activities.
External QC circle competition
(All Japan QC Circle Conference)
At the All Japan QC Circle Conference, which is attended by the
top circles in Japan, the Inabe Plant won the Director’s Award
First Prize for 4 consecutive years (a first for Japan).
Scene of presentations
(at Tokyo Big Sight)
The Eight Samurai Circle receiving
the Gold Medal
(Inabe Plant Assembly Sect. No. 1)
19
Numbers of Toyota Auto Body employees
assigned overseas:
Global Human Resource Development
We are working on global human resource development to
Belgium: 2
Thailand: 18
expand the overseas operations of the entire Toyota Auto
Bahrain: 1
Body Group.
USA: 25
China: 9
Taiwan: 3
India: 1
Loaning employees for overseas development training
Indonesia: 16
As one means of rapidly developing personnel who are capable of
operating our business overseas, in fiscal year 2011 we introduced a
system of sending younger employees on loan to overseas companies.
So far, 26 younger employees have been sent, and have expanded
their areas of activity following their return as they make use of their
training experience in work related to our overseas business.
Malaysia: 9
Australia: 1
Comments from trainees:
Nobuaki Nishioka, Legal & Property Control Dept.,
General Administration Div. (Thailand: TAW)
Studying a response to a revision
of the law
(Mr. Nishioka is 3rd from right.)
Initially, it was a continual
struggle as I was not able to
properly express my
thoughts. As I worked, I was
able to feel the differences in
thinking that result from
different cultural
backgrounds. I intend to
learn and absorb as much as
I can while I am here.
Jun Wakabayashi, Vehicle Planning & Production
Engineering Div. (N. America: TEMA)
Discussing new plant specifications
(Mr. Wakabayashi is 2nd from right.)
I am gaining extremely
valuable experience in
the design of a new
plant. I will take the
experience and
knowledge that I gain
back with me and apply
it in my future work.
Loaning employees for design training
ICT system
The Design Division sends trainees to work at a North
America design studio (CALTY) of Toyota.
Toyota Auto Body has established a system of ICT (intra-company
transfers) for accelerating the independence of overseas affiliates.
In order to handle the
global projects that are
growing in number year by
year, trainees gain practical
experience aimed at
developing the
idea-development ability,
expression skills, and
presentation skills needed
to compete globally.
The Inabe Plant has accepted
5 TAW employees from
Thailand, and conducted
training for them over
approximately 6 months.
Through practical experience,
the trainees acquired
knowledge and skills related
to manufacturing in Japan,
aiming for self-reliance of the
next plant/manufacturing
preparation project in the
local areas.
Trainee (at right) discussing design
ideas with local staff
Thai ICT trainee (2nd from right)
reporting the results of training at
the Inabe Plant
Enhancing overseas communication skills
English training is conducted for all personnel
who support overseas business, aiming to
achieve a level where they can carry out
overseas work without an interpreter.
Instructors who are native speakers of English
teach a technical course centered on English for
technical instruction, and a skills course for
learning basic English conversation and English
for teaching skills.
Improving English skills through conversation
with instructors who are native speakers of
English (Kariya Training Center)
English training for engineers
(Technical Training Center)
20
Creating Strong Workplaces with a High Awareness of
Compliance and Disaster Readiness
Improving Compliance Awareness among All Employees
We have established the Corporate Ethics Committee as a subcommittee of the CSR Committee, and hold discussions and set
directions for activities aimed at improving legal compliance and building a healthy corporate culture. We are endeavoring to improve
compliance awareness throughout the entire Toyota Auto Body Group. Additionally, we are continuing to ensure complete compliance
among our employees via education and training related to ”Our Promise”(the Toyota Auto Body Group Action Policy).
Toyota Auto Body Group Action Policy (Issued March 2005)
Expanding programs aimed at ensuring compliance
As business becomes increasingly globalized, we are working to
improve compliance awareness in the Toyota Auto Body Group both
in Japan and overseas.
Examples of programs for
raising awareness among
overseas employees
In Japan, tools for promoting independent compliance activities
have been created, regular monitoring is carried out, and other
steps are taken to maintain and improve the level of these activities.
Overseas, programs based on the Japan programs are carried out
to improve employee awareness.
Further enhancement of corporate ethics
consulting services
Improving Disaster-Readiness Awareness
through Practical Training
Person
consulting
Pattern 2:
Person
consulting
Pattern 3:
Person
consulting
Internal
investigation
In-company
advisory service
Honto
COM Net
External consultation
service provided
by lawyers
Corporate
Ethics Hotline
Consultation
Consulting
person
desires
anonymity
Consultation
Consulting
person
desires
anonymity
Toyota direct
advisory service
Toyota
Consolidated
Helpline
Deciding and implementing
a response
Aiming for more precise responses, in January of 2013 we
established the Toyota Consolidated Helpline, which allows direct
consultation with Toyota Motor Corporation for matters too
difficult to present to the internal consulting services.
Pattern 1:
Activity for preventing
bribery through posters
Investigation of facts
To provide a system for proper handling of labor problems and
other topics that are difficult to discuss with supervisors and/or
colleagues, we have established the Honto COM Net direct email
consulting service as well as the external legal consulting service
Corporate Ethics Hotline provided by lawyers.
A meeting regarding compliance
activities (overseas)
Important matters
are investigated
by Toyota.
Consultation
Consulting
person’s
name required
3 patterns of corporate ethics advisory services leading
to an internal investigation
Aiming to minimize increasingly diversifying risks, we in the Toyota Auto Body Group are working to expand and strengthen risk
management as one part of our internal controls. We assess and identify any risks that could impact company operations, and establish
preventive measures and initial response measures to address them. The disaster-readiness training for initial response measures is being
made increasingly realistic year by year.
Comprehensive disaster drills vital in case of a large-scale earthquake
In recent years as we make the training increasingly realistic, we have incorporated training with no advance notice, simulations of cases
when some parts of an escape route cannot be used, and small group outdoor evacuation that facilitates rapid action. Training to
centralize safety confirmations for all employees in each workplace and to notify the all-company disaster countermeasures headquarters
is conducted at each business location and subsidiary company. We have also concluded a disaster-readiness agreement with Kariya
City for the provision of accommodations, food, and water in the event of a disaster.
Comprehensive disaster drills (at Toyota Auto Body):
Initial firefighting
training
(fire extinguishers,
fire hydrants)
All employees evacuating to the
outdoor evacuation site in small groups
Outdoor evacuation (overall scene)
Transporting injured persons
Training for installing rescue chutes
21
Putting Safety First and Working to Create Safe
People and Workplaces
All suppliers and overseas subsidiaries are carrying out activities aimed at eliminating
accidents, including strengthening of efforts by top management to create a safety-first
environment, and activities to improve safety sensibility among individual employees.
Achieving Safety First for All Employees
Efforts by top management to create
a safety-first environment
At our company-wide Safety Rally, Toyota Auto Body
executives, department and section managers, and top
management of our affiliated companies together recited a
slogan describing the importance of basic safety activities,
with the objective of eliminating dangerous incidents.
We are also taking the lead with Safety Month, and with
personal checks of workplace problems by the company
president that are linked to improvements.
Company-wide Safety Rally in July 2014
A check of safety activities by the
company president (Safety month, July)
Activities to improve safety sensibility
We are making efforts aiming to create a company culture
in which employees warn colleagues who are unaware of
safety risks around them. We call these activities
Po-ke-te-na-shi*1, and each of these five parts
corresponds to a set of basic safety activities.
*1: Po : Do not put your hands in your pockets while walking
ke :
te :
na :
shi:
No use of keitai (cellular phone) while walking
Hold the tesuri (railing) while climbing and/or descending stairs
No naname (at an angle) crossing of a street or road
Be certain to shisakoshou (point to the left and right and call out
when one intends to cross a street or road)
Banners for an awareness
and action campaign
Activities aimed at increasing the safety sensibility of all employees include
having employees consider safe procedures for the use of tools and training for
finding irregularities in the workplace. We have also launched a system for
level-based KY (kiken-yochi: danger prediction) training in which individuals
assess their own KY levels, and are working to improve individual skill levels.
KY training where
employees consider
danger based on actual experience
(example of crowbar handling and
transporting large workpieces)
Putting Safety First for our
Business Partners
Based on our own objective of zero shipping-related
accidents at our facilities, we are coordinating safety
programs with suppliers, externally contracted construction
companies and shipping agents. For construction safety
during extended shutdowns (when accidents are especially
likely to occur), we carry out safety checks (rallies) and other
activities to improve safety management.
Special morning safety meeting
for work during the winter holidays
Forklift safety rules study meeting for all
shipping agents
(Technical Training Center)
Putting Safety First in Overseas
Operations
Internal company activities are also carried out overseas.
Under the direct leadership of top management, activities
including safety inspections by the company president,
recitation of safety slogans at morning meetings, 4S, and
Po-ke-te-na-shi are used to help create a culture of watching
out for one another in which all employees participate.
Safety and Health Policy
Safety inspection by top management
in Indonesia (RPT)
Reciting safety
slogans at a
morning meeting
4S activities
Labor Accident Status
22
Ensuring the Mental and Physical Health of our Employees
We recognize that the health of our employees is an important element in our quest to
create ever-better cars, and we have enacted a variety of programs aimed at making us
a healthy company as we work to ensure the health of all employees and their families.
For the Health of our Employees and their Families
We are carrying out a variety of activities aimed at developing
employees who are capable of independently maintaining and
improving their own health. These are based on three key activities:
maintaining and improving mental health, improving lifestyle habits
(preventing metabolic syndrome), and stopping smoking.
We also hold instructional meetings regarding ways of preventing the
back pain that occurs often in the manufacturing industry, walking
events sponsored by the Health Insurance Association, and
health-promoting events where family members can also participate in
connection with the all-company sports day.
Instruction meeting for prevention of back pain,
conducted by an exercise instructor
Aiming for easily approachable consultation offices
We have created a consultation system, with clinical
psychologists who are experts in mental health assigned
to the Fujimatsu, Inabe, and Yoshiwara plants.
So that employees will come for mental health
consultations, the clinical psychologists introduce the
consultation offices at health events, in lectures by
psychologists to key personnel, during workplace
training, and at other opportunities, aiming to create an
atmosphere for easily accessible consultations.
Promoting health awareness through
family participation events and outside
health workshops
Stress check (stress evaluation by
measurement of saliva components)
Conducting stress check!
Mental health lecture
for key personnel
In connection with the all-company sports day, we also
hold health measurement events that family members
can also participate in as opportunities to reconsider
lifestyle habits.
We are also actively carrying out activities to promote
employee health awareness, including AED training in
the workplaces, and health workshops for smoking,
metabolic syndrome, and dental health.
Support for quitting smoking and
creation of separate smoking and
no-smoking environments
To help create new non-smokers, the 22nd of each
month has been designated as a company-wide
no-smoking day, providing opportunities for employees
to quit smoking. Anti-smoking examinations are also
performed at the company clinics in order to provide
support for employees who want to quit smoking.
The company is also divided into smoking and
non-smoking areas in order to prevent passive smoking
by non-smokers.
Health measurement at the
all-company sports day
Workplace AED training
The 22nd of each month
is the Toyota Auto Body
non-smoking day.
The 22nd of each month has been designated
as the“Toyota Auto Body non-smoking day”.
On this day, please refrain from smoking
anywhere on company grounds.
FY 2015 designated
non-smoking days
Company-wide no-smoking day poster
The shape of the number“22”resembles
two swans. The word“swan”sounds like
the word“suwan”(I don’t smoke) in
Japanese.
Examinations for employees who
want to quit smoking: measuring
breath CO concentrations
(Measured to check the effects
of quitting smoking.)
23
Communication Activities for“Creating a Vibrant Workplace”
In order to create a vibrant workplace culture that supports the happiness of each individual employee
and the development of the company, we are attempting to breed a sense of unity by creating various
opportunities for invigorating communication that exceeds the framework of the workplace and rank.
Targeting a Workplace with Open Communication
Creating Vibrant Workplaces via Communication Activities
(Formal activities)
We are enhancing communication through things such as
daily workplace meetings, interviews with superiors, and
small group activities.
Aiming for Cheerful, Fun,
and High-Spirited Workplace
<Vibrant Workplaces>
Workplace Human resource
energy
development
Teamwork
Management
Reliable Personnel Management by Production Line
Workplaces with a positive atmosphere
<System and Tools>
Communication to
guarantee work results
(Informal activities)
We are enhancing communication and breeding a sense of unity
through company-wide, office-wide, and intra-division events held
away from work.
Communication to
improve human relationships
Formal Activities
(MBO and challenge sheets/C Meetings)
Informal Activities
All Toyota Group:
Company-wide:
All Toyota Big Holiday
The all-company sport day
(Fure-Ai Sports Day),
held for the first time in 15 years
Business site events:
Division events:
Events that highlight the unique characteristics
of each office
Toyota Auto Body Group sports competitions:
Toyota Auto Body Group Futsal Tournament
Yoshiwara Plant
Festival
Development division marathon
Fujimatsu Plant
tricycle race
Sports club supporters
TOPICS
Providing information in the cafeterias
TAB channel for this week
(1)
(2)
(3)
(4)
(5)
(6)
Joint report meeting by handball and volleyball teams
Queenseis and Kurowashiki All Japan Tournament
Information on HAPPY FESTA
Real estate information from Toyota home
Introduction of the 70the Anniversary goods
Information on recreational facilities
Informal activity information is
provided by video in all the
cafeterias, creating opportunities
for communication.
The launch of programs for the 70th Anniversary
Year of Thanks (2015)
Company events and division
events are held to express
thanks to our roots
(predecessors) and thanks to
our coworkers, and to connect
these feelings of gratitude to
our future dreams.
Activity for producing original seasonal decorations
in the production engineering divisions
24
Creating Awareness and Easy-to-Work Environments
to be“Good Members of Society”
We are striving to create awareness for being good members of society by doing things such
as deepening awareness of human rights and enhancing awareness of traffic safety.
In addition, we are making efforts to enrich various measures for creating easy-to-work
environments for our employees.
Being Good Members of Society
Deepening Awareness of Human Rights
Aiming to improve awareness of“Respect for Individuals”we
are providing internal training for all employees concerning
various human rights issues, including social integration issues
and humans rights for women and foreigners.
Human rights education
(new position training)
Discussion at a C meeting
Employee traffic safety activity
Lecture by persons who lost
family members
Ensuring traffic safety awareness
Aiming to improve traffic safety awareness, in addition to our
traffic safety activity, we have held lectures by persons who
have lost family members in traffic accidents and who describe
their sadness and pain in their own words, as part of
educational activities to eliminate traffic accidents.
Creating Environments to Support Diverse Working Styles
Support for the working styles of older employees
Creating processes that are easier to perform:
So that all employees can continue working in good health,
we are carrying out process improvements that lessen work
burdens, for example by improving work that is performed in
difficult positions.
Creating workplace awareness for preventing loss of physical
strength:
Awareness seminars are held for employees in their 40s and
50s, teaching ways of working and building strength so that
they can continue to do the same work when they are 60 and
older. So that employees can achieve the second life that
they want, we provide opportunities for them to learn about
the necessity of self-help efforts and to begin putting them
into practice.
Expanding support for child raising
Lifted up
Process improvements:
The vehicle body is raised and
lowered for each work position
(height), reducing the burden
on the worker’s body.
Lifted to a height where work is easier (tire installation process)
Guidance for building body strength at a body awareness seminar
We are promoting improvement of the environment to support
our employees to keep working while raising children by
creating systems that go beyond established laws, such as
establishing the internal Tacchi-chi House, a short working
shift system, a maternity leave system, and others.
Especially in this fiscal year, we are providing the childcare
environment that meets various needs by extending the
available hours of daycare facility according to the shiftwork,
offering temporary childcare on a public holiday, and other
services.
Joint daycare facility Tacchi-chi House Fujimatsu
Support for Pregnancy, Childbirth and Child Raising
25
■Social Contributions
Aiming to be a Company and People That are Needed by Society
In order to be a company needed by society, we consider it important to fulfill our social
responsibility to earn the trust of everyone in the local communities.
In order to achieve a mutually beneficial relationship with local communities through activities that
contribute to society, we are developing people, creating opportunities, and creating systems for
further strengthening these activities.
Developing People
Expanding courses that support activity participation
We hold 60 courses a year to support participation in volunteer activities. These courses include basic courses,
skill-improvement courses in specialized areas, and leader training courses. Through these courses and experience activities,
we are building empathy and developing personnel who can participate in activities for the benefit of society.
Forest maintenance course
For the forest maintenance activities conducted by
employees of companies in Aichi Prefecture, this
course develops leaders who can conduct safe
woodland thinning activities and creates a system
(knowledge, practice, continuation) so that
employees participating for the first time can
experience woodland thinning under the guidance
of the leaders.
Introductory courses for each generation
Knowledge:
Learning about the necessity of
forest maintenance
A volunteer activity experience program is
conducted as part of the training for new
employees. Employees select from a list of 28
activities including NPO support and operation of
sports competitions for disabled persons, and
themselves create and carry out a participation plan.
Comment from a new employee participating
in a volunteer activity
Production Control Div.
Shinichi Ohmura
No. 11: NPO support (pastry sales)
Date: 11/8 (Sat) 9:00 – 16:00
Place: Ohkagakuen Nagoya Two-year College
Activity: Sales of NPO Pandora products
Transport, venue operation, cleanup
Selecting from 28 activities and creating a participation plan
Practice:
Understanding the health of a forest
based on leader instruction
PR support for NPO activities
at a university festival
Participating in this
activity has changed
the way I think about
volunteering and how
I spend my days off.
In the future, I would
like to make use of
my own interests and
participate actively.
Creating Opportunities for Activities
Toyota Auto Body Group programs
Both in Japan and overseas, we are engaged in
forest maintenance, environmental preservation
activities, and the“Fure-Ai Day”volunteer day for
the entire group, and are conducting activities that
involve employees, their families, and members of
the local communities.
Toyota Auto Body R&D
Kinko Bay cleanup activity
Indonesia mangrove planting
conducted by 3 overseas
subsidiary companies
26
Creating Opportunities for Activities
Creating opportunities centered on the workplaces (blocks)
Centered on business sites and workplaces, we are carrying out activities together with members of the local communities.
Environmental beautification
Employees and their families carry out cleaning
and greening activities in the areas around the
plants together with members of the local
communities.
The Inabe“cleanup along the Hokusei Line”
activity was awarded the 5th Make a CHANGE
Day award of excellence for its coordination
and cooperation with local communities and
government.
Inabe:
Cleanup along the Hokusei Line
Yoshiwara:
Making a green corridor along the
Aizumaogawa River
Activities for community and raising the next generation
As an important activity for interacting with
youth in communities, Toyota Auto Body
supports youth soccer tournaments, and our
handball and volleyball club members conduct
sports classes. In addition, the Toyota Auto
Body Group jointly presents concerts with the
Nagoya Philharmonic Orchestra, which persons
with physical and mental disabilities are invited
to attend.
Winning team at the Kariya City
Toyota Auto Body Cup
youth soccer competition
Community concerts
Creating Systems for Revitalization and Continuation
Programs using our facilities carried out in cooperation with local
communities, and programs to improve environmental awareness
At Kariya Fure-Ai Park, we conduct agriculture
experience programs and environmental workshops
for employees and their families, members of local
communities, and students of nearby elementary
and junior high schools throughout the year.
Participants learn about the blessings of nature and
rice cultivation from local agriculture instructors.
In addition, we have completed the Forest
Classroom at the Inabe Plant, and are using it to
Woodworking craft class using the completed Forest Classroom (Inabe Plant)
hold environmental workshops and woodworking
craft classes.
27
Creating Factories that are Harmonized with Nature
and Coexist with Local Communities
We are all a part of nature, sharing it with the many creatures that live in it. In order to protect the
environment of our communities so that people and nature can coexist, we at Toyota Auto Body
are coordinating with local communities to create factories that exist harmoniously with nature.
Kariya: Operation of the Kariya Fure-Ai Park for learning and relaxation
The Kariya Fure-Ai Park opened in May 2014.
Total area: Approx. 50,000 m2
Based on a concept of harmony between people and
Biotope and Fure-Ai Area:
Approx. 15,000 m2
nature, it is used as a place for agriculture experience
programs, environmental workshops, and community
interaction events.
Biotope
Wooded area
with a small stream
The biotope was also created to contribute to the
creation of a network that connects the green areas of
the factory and surrounding green areas. Such
networks are one part of the Aichi Prefecture
Futsal and
tennis courts
Rice paddy field
biodiversity strategy.
Fure-Ai Area
Fruit orchard and
agricultural field
Community contributions and collaborations using our facilities
The park provides a place for elementary school
students to learn about rice cultivation throughout
the year, including planting, harvesting, threshing,
and hulling, and also about traditional Japanese New
Year customs such as making mochi (rice cakes) and
weaving ceremonial ropes as part of their social
studies classes.
Using the biotope and other resources of the park,
Year-long agriculture experience: Rice planting (June) September: Harvesting
environmental workshops are also held for members
of local communities, students of nearby elementary
schools, kindergartens, and employees.
In cooperation with the Aichi University of Education,
the park is also used as a place for instruction in
environmental preservation techniques and for
research presentations. At the end of the academic
year, an event where graduates present their theses
is held, improving everyone’s understanding of
Students making mochi from the rice
that they planted themselves
biodiversity.
Weaving ceremonial ropes using
rice straw from the rice field
Comment from a Fure-Ai Park user
Kariya Municipal Fujimatsu Higashi
Elementary School Principle Nomura
The children gained valuable
experiences with nature and
agriculture through outdoor
learning that cannot be
done in a classroom.
Nature observation program taught
by students from Aichi University of
Education
Research thesis presentation
on the subject of biotopes
28
■Friendly to the Global Environment
Maintaining a Society of Prosperous
and Convenient Living into the Future
One of the fundamental principles of Toyota Auto Body is harmony with the
environment, and in keeping with the ideals of our predecessors we began carrying
out the Fifth Toyota Auto Body Environmental Action Plan beginning from fiscal year
2011. Aiming for the sustainable development of society and the world, we are
introducing new technologies at times when new products are produced or equipment
Production Engineering Headquarters
is replaced, and we are working to preserve the global environment through activities
Production Environment Committee Chairperson:
which involve all employees. In the future, we will continue to work together with
Akitsugu Ishiguro,
members of local communities and continue building a prosperous society.
Toyota Auto Body Basic Environmental Policy (Established in 1993, Revised in 2004)
(1) Contributing to a prosperous 21st century
(3) Self-initiated efforts
To contribute to a prosperous 21st century, we aim for growth in
harmony with the environment, and are challenging ourselves to
achieve zero emissions in all areas of our business activities.
Starting with our efforts for thorough preemptive prevention and
c o m p l i a n c e w i t h l e g a l s t a n d a r d s , w e h a v e e s t a b l i s h e d s e l f - i n i t ia t e d
kaizen plans based on global-scale environmental issues, and we
continue to promote such self-initiated efforts.
(2) Pursuing environmental technolog
(4) Coordinating and cooperating with society
Toyota Auto Body is pursuing all potential environmental
technologies and we are making efforts to develop and establish
new technologies that realize a balance between the environment
and economic concerns.
Beginning from cooperation with affiliated companies and
industries, we are building cooperation and coordination with a
large sector of society involved in environmental conservation that
includes the government and prefectural governments.
Toyota Auto Body Environmental Action Plan
As we aim for the sustainable development of society and the world through environmentally friendly manufacturing,
we have established action items in each field (development, production and logistics, and procurement), and are
continually carrying out comprehensive environmental management.
1993
1995
First Plan
◇Construct a system
for environmental
programs.
2000
Second Plan
◇Improve the level of
the programs by
introducing
ISO14001.
2005
Third Plan
◇Achieve zero landfill
waste and expand the
areas of environmental
activities.
Building a low-carbon
society
2010
Fourth Plan
◇Work to reduce CO2
emissions on a global
basis, and apply
environmentally friendly
designs to our products.
Building a recyclingoriented society
2015
Fifth Plan
◇Promote to develop a compact EV
◇Build a prosperous society
through activities
conducted together with
local communities.
2020
Sixth Plan
(Now being
formulated)
Building a society that lives
in harmony with nature
Product
environment
(development
and design)
・Improve fuel efficiency by reducing ・Improve ease of vehicle dismantling ・Improve the management of products
vehicle weight
containing chemical substances
・Expand use of recycled materials
・Participate in projects for promoting ・Develop materials using plant fibers ・Introduce products that contain fewer
the introduction of super-compact
substances that impact the environment
mobility
Production
environment
(production
and logistics)
・Develop/introduce production
・Reduce environmental-impact
・Carry out activities to reduce
technology that reduces greenhouse
emissions and improve yield
substances (VOC) in painting operations
gas emissions, improve productivity,
・Reduce
the
amounts
of
packaging
and intensify energy-saving activities
materials used
・Improve transport efficiency in our
logistics operations and switch to
electric vehicles for on-site logistics
Environmental
management
(Environmental
administration)
・Promote and improve consolidated environmental
management
・Create factories that coexist with local communities
and are harmonized with nature
・Enhance and promote environmental education and
training
・Promote further environmental activities that are
coordinated with suppliers
Fifth Toyota Auto Body Environmental Action Plan
Product and Production Environmental
Action System and Items
Fiscal Year 2014 Action Results
29
Recycling
Three Priority Themes: Low Carbon Orientation
Product Environment
Harmony
with Nature
Development of Weight-Reducing Technologies that
Contribute to Top-Class Fuel Economy Performance
Energy and global warming problems are important environmental issues that may have a major effect on
humanity and the ecosystem. In cooperation among related divisions, we are developing technologies
and working from the initial design stage in order to create environmentally friendly vehicles.
Developing Weight Reduction Technologies for Vehicle Parts
Improving the power train and reducing vehicle weight are essential in order to improve
fuel economy. We consider reducing the weight of vehicle parts as a core approach of
Toyota Auto Body, and the entire company is actively working for this purpose.
Main programs for reducing the weight of re-designed
Alphard and Vellfire body and interior parts
By using high-strength steel sheets for approximately
62% of the underbody (by weight), and by improving
the structure and reducing the thickness of interior
parts, we achieved a weight reduction of 32 kg.
The use of high-strength steel sheets also efficiently
increases rigidity, creating a lightweight and strong
body while also ensuring collision safety performance.
32kg
reduction
Body:
Discussion of the re-designed Alphard and Vellfire
weight reductions involving officers of the
development and production engineering divisions
Upper body
Doors
High-strength
steel sheets
1500MPa
（hot stamping *1）
980MPa
590MPa
Previous
technologies
Re-designed
Alphard and Vellfire
440MPa
*1 .Hot stamping: A part forming
method where steel softened by
heating to a high temperature is
press formed and, at the same
time, hardened by cooling when it
comes into contact with the die.
Comment by a the re-designed
Alphard and Vellfire developer
Body Design Div. Makoto Murakami
We were able to achieve
a large reduction in
weight by coordinating
with related divisions
beginning from the initial
development stage,
using high-strength
steel sheets, and
optimizing part layout.
Under body
Interior:
Thinner, one-piece
instrument panel
Thinner,
scuff plate
Old model: Separate upper/lower
structure
Upper
instrument panel
Lower
instrument panel
Thinner trim
base material
(0.2 reduction）
Deck board
Uses lightweight
PP bead foam.
Lower density by joining the floor carpets together
New model: One-piece upper/lower forming
Increasing the strength of
the unit part allows thinner
material, reducing the weight
by approximately 3 kg.
30
Recycling
Product Environment
Harmony
with Nature
Expanded Use of Recycling-Friendly Designs for
Efficient Use of Resources
Because we understand that all resources are finite, based on the 3 R’ s (reduce, reuse,
recycle), we are working to improve the ease of dismantling, expand the use of recycled
materials, and develop and design plant-fiber materials.
Improving the Ease of Vehicle Dismantling
As heavy machinery for vehicle dismantling has become widely used in the markets,
we are working in cooperation with Toyota to develop vehicle structures that can be
dismantled more easily.
Improving the ease of wiring harness dismantling with heavy machinery
Green tape is used at key positions to show where wiring harnesses can be
removed efficiently when scraping the re-designed Alphard and Vellfire,
improving the ease of dismantling.
Video Showing the Use of Heavy
Machinery for Vehicle Dismantling
Instrument panel wiring harness
Expanding the Use of Recycled Materials
Green tape is added at the wiring
harness positions to shown the
starting points for easy removal
3. Rear floor under-cover RH/LH
Expanding the use of recycled materials made
from waste plastics and felt from the market
2. Fender protector
RH/LH
The re-designed Alphard and Vellfire use recycled
polypropylene and recycled felt, increasing the use
4. Dashboard
silencer
of recycled materials.
5. Felt
1. Floor under-cover RH/LH
Parts 1 to 3: Polypropylene (bumper, other recycled materials)
Parts 4, 5: Recycled felt
Development of Materials using Plant Fibers
Use of cedar from woodland thinning
We have developed the new flame retardant injection molding material TABWD *1. This
material uses cedar from woodland thinning as a reinforced fiber in combination with
polypropylene. It is used in the wiring harness protectors in the re-designed Alphard
and Vellfire hybrids, as we continue to work for more effective use of resources.
Fine cedar fiber
TABWD
Wiring harness protector (Black parts are
where the developed material is used.)
*1.TABWD：Toyota Auto Body WooD plastic
Comment from a TABWD developer
New Business Development Div.
Takuya Nishimura
In the future, we
intend to expand the
range of products
which use this
injection molding
material made with
cedar from woodland
thinning, and will
propose new ways of
using it that will lead
to more effective use
of resources.
31
Recycling
Product Environment
Harmony
with Nature
Start of a Recycling Business for the COMS Super Compact EV
The COMS Recycling System that was launched in April 2015 is an original recycling system constructed by
Toyota Auto Body for the COMS ‒ a vehicle which is not subject to the Automobile Recycling Act. We will
continue to work for the creation of a recycling-oriented society in the future.
Process of COMS recycling
Intended COMS lifecycle
Processing
facility
COMS Recycling System
Development
and design
Recycling
Toyota
Auto
コ
Body
Manufacture
Collection
Customer
Scrapping
Customer
Recycled
materials Recycling rate
Toyota Auto Body
タル
Call
セ
Center
ン
Sale
Processing
and
recycling
facility
iron,
aluminum,
others
80% or higher
Waste
materials
Suitable
disposal
Use
COMS Recycling System web site
We have acquired a national permit from the Ministry of the
Environment and constructed a recycling system which
customers in all parts of Japan can use.
Three Priority Themes: Low Carbon
Recycling
Orientation
Harmony
with Nature
Improving Management of the Chemical Substances
Used in Products
We at Toyota Auto Body are coordinating with our raw material and parts suppliers to
identify and assess the risks of the chemical substances that are used in our products,
and we are working to protect the environment via actions such as managing chemical
substances and changing to the use of substances with lower environmental impacts
Certain Compliance with REACH Regulations and
Other International Chemical Substance Regulations
Regulations of chemical substances include the Japanese Chemical
Substance Control Act*1, the European ELV Directive*2, and the
REACH Regulations*3, as well as independent regulations in North
America and Asia.
Toyota Auto Body is working together with Toyota Motor Corporation
and our suppliers to build and administer a system for chemical
substance management under these kinds of international chemical
substance regulations.
In fiscal year 2014, we standardized our compliance with chemical
substance control regulations, and established firm practices for IMDS*4
registration by suppliers as we collect information about the chemical
substances that are used in our products.
Based on green purchasing guidelines for
environmental preservation, we are supporting
the introduction of chemical substance
management systems at subsidiary companies.
*1.Chemical Substance Control Act: Act on the Evaluation of Chemical Substances and Regulation of Their Manufacture, etc.
*2.ELV Directive: End-of-Life Vehicles Directive
*3.REACH Regulations ： Registration,Evaluation,Authorization and Restriction of Chemicals
*4.IMDS ： International Material Data System
32
Recycling
Production Environment
Harmony
with Nature
Extensive energy-saving and CO2 emissions reductions
in production activities
We are developing and introducing technologies for low-CO2 production, improving production line
productivity, fully eliminating waste in everyday activities, and promoting optimal equipment operation.
CO2 reduction activities launched with the start of production for the re-designed
・Introduction of new machining methods at the start of production of new vehicles (Examples (1) (2))
・CO2 emissions reduction and increase in the self power-generation rate with a new cogeneration system at the Inabe Plant (Example (3))
・Extensive reduction in power and air leakage loss between shifts and on holidays (Example (4))
CO2 emissions (Toyota Auto Body)
CO2 emissions per vehicle (Toyota Auto Body) CO2 emissions per vehicle (Inabe Plant)
(Thousands tons CO2)
（Comparison of CO2 emissions before
and after start of production (SOP)
of the re-designed Alphard/Vellfire）
(CO2 kg/vehicle)
350
300
317
201
∼
∼
200
219 219 213
200 208
295
191
300
(CO2 kg/vehicle)
295
280 269 283 289
37
reduction
258
(285)
13%
energy
savings
250
100
∼
∼
∼
∼
∼
∼∼
0
0
'10 '11 '12 '13 '14 '15
'90
'10 '11 '12 '13 '14 '15
'01
(Target)
Before SOP
(Feb. 2014)
(Target)
After SOP
(Feb. 2015)
Example (1): Energy savings resulting from integrated forming of the instrument panel upper and lower parts:
＜Now＞
＜Previous＞
Integrated
forming part
Forming machine
Lower part
Forming machine
Upper part
Upper part
Improved resin flow performance makes forming
of a large-size instrument panel possible.
Upper part forming
Integrated forming of upper/lower parts
Instrument panel weight reduction
1.8
reduction
6.6
Forming machine
Lower part
Lower part forming
CO2 reduction
(CO2 t/Year)
(kg)
2.7
Lower
4.8
3.9
Upper
Previous
Now
42
reduction
185
27%
weight
reduction
Integration,
reduction
in thickness
23%
energy
savings
143
Number of
forming processes
reduced by 50%
Now
Previous
Example (2): Energy savings resulting from improved method for heating of vacuum forming base material:
Previous (overall heating)
Hot air
heating
Now (local heating)
Far-infrared
heating
270 seconds to
reach target
heating temp.
(65 ℃)
Instrument
panel
Slides
15 seconds to
reach target
heating temp.
Far-infrared
(65 ℃)
heater
Instrument
panel
Heating oven
CO2 reduction
Use of a far-infrared
heater capable of
rapid heating
(CO2 t/Year)
25
reduction
32
78%
7
Previous
energy
savings
Now
33
Production Environment
Recycling
Harmony
with Nature
CO2 reduction activities launched at the start of production for the re-designed
Example (3): CO2 emissions reduction and increase in the self power generation rate
with a new cogeneration system at the Inabe Plant:
A new gas engine cogeneration system has started operating at the Inabe Plant (from Jan. 2015).
It will contribute to further reducing CO2 emissions in the future.
System characteristics:
・Overall efficiency is 80% of the maximum for the gas engine class. The expected annual reduction in CO2 emissions
is 11,000 tons.
・A model with a large generating output is used, increasing the self power-generation rate to 32%.
・A system capable of supplying power during blackouts in the event of a major earthquake or other disaster was adopted.
Overall efficiency 80%
Electricity
Plant
49%
Steam
Steam recovery
from waste heat
7.5 MW
generation
City
gas
Gas
engine
exhaust
gas
300℃
Painting booths
14%
Waste heat
boiler
90℃ hot water
Winter
（Engine coolant）
Plant A/C
13%
The latest gas engine system with a
generation efficiency of 49%
Summer
Hot water driven
absorption chiller
60℃ hot water
Winter
（Lubricating oil coolant）
Plant A/C
Plant A/C
4%
Example (4): Extensive reduction in power and air leakage loss between shifts and on holidays:
In fiscal year 2014, benchmark targets were set for each shop at the Fujimatsu, Inabe, and Yoshiwara Plants, and
as a result of the efforts below we succeeded in achieving a 500-ton annual reduction in CO2 emissions.
・Voluntary inspections for early repairs of air leakage
・Providing weekly and monthly results data to make the effects of
activities visible
・Genchi-genbutsu energy-saving inspections by officers at each plant
to create awareness and motivation for energy-saving activities
Example: Amount of air leakage per hour in stamping and
body processes at Inabe Plant (indicator)
19% decrease
100
81
Results of determined
energy-saving activities
Genchi-genbutsu energy-saving
inspections by officers
(March 2015)
Now
Previous
(Dec. 2013) (March 2015)
34
Environmental Management
Strengthening Consolidated Environmental Management
We have created a management system that coordinates our subsidiaries in Japan and overseas,
and suppliers, and are actively carrying out activities including (1) educational activities aimed at
raising the level of environmental action, and (2) activities to prevent environmental risk.
Introduction of an awards system
Into raise the activity level
company
Japan
Overseas
subsidiaries subsidiaries
Beginning from fiscal year 2014, we set up a system of awards for
workplaces that contribute to environmental preservation programs,
aiming to raise the level of these activities.
Awards were presented to workplaces that achieved large reductions
in energy loss when equipment was not operating (Yoshiwara
Plant’s Final Assembly Div. and Inabe Plant’s Stamping Shop).
Awards ceremony (Feb. 2015)
Environmental education activities
A variety of educational activities are
carried out to correspond with Environment
Month.
Activities at the award-winning workplace:
Air leakage inspection (Yoshiwara Plant’s
Final Assembly Div., Sep. 2014)
Japan
Overseas
Incompany subsidiaries subsidiaries
In fiscal year 2014, lectures on the subject of The Present and
Future of Global Warming were held, presenting an excellent
opportunity for employees to understand the facts about global
warming and renew their recognition of the need for energy-saving.
WWF Japan: Lecture by Ms. Konishi (Aug. 2014)
Activities to prevent outflow InJapan
Overseas
company subsidiaries subsidiaries
of chemicals, production
wastewater, and other contaminants
Aiming to prevent outflow from production processes, chemical
storage areas, and other places, in addition to carrying out daily
management, we have also decided procedures in case of spills to
ensure that contaminants do not leak from the company grounds,
and are conducting systematic emergency training for rapid
action. In fiscal year 2014, these activities were also carried out
at overseas subsidiaries.
Training to prevent wider contamination in the event of a spill
Kariya Plant (Aug. 2014)
TAW (Oct. 2014)
Strengthening management InJapan
Overseas
company subsidiaries subsidiaries
including at subsidiary
companies in Japan and overseas
We continued to acquire ISO14001 certification at our production
sites. In fiscal year 2014, the certification was newly acquired by
three overseas subsidiaries, and certification has now been acquired
by all production sites.
Through liaison meetings and on-site audits, the contents of programs
at consolidated companies in Japan and overseas are checked
regularly. Environmental improvement case studies and other
information are also shared, and environmental training is conducted.
ISO14001 certification acquired
by APMM (Feb. 2015)
On-site audit T-TEC
（Sept. 2014）
Other Environmental Data
Resource Investment into and Emissions Produced
by Our Business Operations
Active Release of Environmental Information
Environmental Accounting
35
In order to utilize the valued opinions of all readers to enhance further and
reflect information more accurately for these CSR activities and this report
of Toyota Auto Body for the future, please enter information in the survey.
The opinions and information provided will only be used for the purpose mentioned above.
(Private information will be handled appropriately pursuant to the Toyota Auto Body“Privacy Policy”)
Please click here to view the survey.
Publishing
Head Office
Toyota Auto Body Co., Ltd.
100, Kanayama Ichiriyama-cho, Kariya City, Aichi Prefecture 448-8666
TEL: +81-566ｰ36ｰ2121
Corporate Planning Division
TEL: +81-566ｰ36ｰ7510 FAX: +81-566ｰ36ｰ9113
Publishing Date
June 2015（Next publishing scheduled for June 2016）
http://www.toyota-body.co.jp/english/

CSR REPORT 2015

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