Toyota Way
Toyota Way
Toyota Way
on Environment Management
Contribution of CO2 Reduction in Manufacturing & Logistic Activities
by Hidematsu Ibaragi (President Director) I Made Dana M.T (Senior General Manager)
Jakarta, November 4, 2008
TOYOTA WAY
Presentation Outline
Page
1. INTRODUCTION.....................................................................................
* TMMIN Company Profile & Product Line Up..
3 3 5 5 10 11 12 26
3. IMPLEMENTATION OF TMMIN ENVIRONMENT ACTIVITIES. > CO2 Reduction in Manufacturing & Logistic Activities. 4. CONCLUSION.
1. INTRODUCTION
Company Profile
Head Office
Jl. Yos Sudarso, Sunter II, Jakarta 14330 Phone (62-21) 6515551 (hunting), Fax. (62-21) 6515360
Total Employee
5,271 persons
Share Holders
Toyota Motor Corporation (95%), PT Astra International Tbk (5%)
Production Facility
Sunter I Plant :
Engine Plant (13,000 Units/Month) Packing Plant (5000 Units/Month) AREA : Land 41,527 m2
Sunter II Plant :
Casting Plant (1,000 Tons/Month) Stamping Plant (8,000 Units/Month) U-IMV Packing Plant (4,200 Units/Month) AREA : Land 129,275 m2
Karawang Plant :
Integrated Mfg. Facility Stamping, Welding, Painting, Assembling CAPACITY AREA : 100,000 Units/Year : Land 100 HA (Used 30 HA)
2004
2005
2006
2007
2008
Th M e Ad ost in mi W r Re orl ed gio d & na Mo l Ha noz En rmo ukur vir ny i in G on wi lob me th S nt OC al W N C s ar m atu H om ing re S um plian Re D ocia an R ce so urc isc l C es with los on our R es ur trib ce eg
TOYOTA MOTOR MANUFACTURING INDONESIA
Monozukuri means more than simply manufacturing products, but instead covers a set of activities and processes, from development through production to sales and service, that create added value to fully satisfy our customers.
CO2 reduction
Issue
Hybrid Technology
Energy issues Biofuels Synthetic fuels CNG DPNR Common rail DI D-4 Lean burn VVT-i EV
Issue
Diesel engines
Gasoline engines
Electrical energy
The Fourth Toyota The Fourth Toyota Environmental Action Plan Environmental Action Plan
Management
Strengthen consolidated environment management
: Focus Explanation
2. TOYOTA POLICY ON ENVIRONMENT b. TMMIN Environment Action Plan ( (Focus Item) b. TMMIN Environment Action Plan Focus Item)
1.Cooperation 1.Cooperation With Society With Society 2.Atmospheric 2.Atmospheric Quality Quality 3.Substance 3.Substance of Concern of Concern
CSR & Community Development Activities Reduce VOC (Volatile Organic Compound) from Painting process Incinerator Recovery Thinner Introduce ESG top coat stack Eliminate SoC in Part (4 heavy metal parameter) SoC free for Investigation & switch over Innova~Fortuner Reduce CO2 emission in manufacturing & logistic activities Manufacturing Alternative Energy Logistic Grasp CO2 data Fuel & truck efficiency Packing materials reduction Target Setting & PDCA Regional No.1 Local No.1 Zero Emission Zero Waste
Water borne
Reduce water consumption & waste minimization Optimize reuse water Waste recycle (Hazardous) Waste Water Management Soil & Air Pollution
Oct. 2007
10
2008
2009
2010
2011
3.1 Cooperation with Society 3.2 Atmospheric quality 3.3 Substance of Concern (SoC) 3.4 Energy / Global Warming
11
3. Implementation of TMMIN Environment Activities 3.1 Cooperation with Society Objective : 1. Empowerment Community Surrounding TMMIN business 2. Perform TMMIN's concern and contribution to the country & society
Example 1)
Greenery Program
Plantation in surrounding TMMIN Location : Karawang Residence
Example 2)
Environmental Improvement Contest for Senior High School student Scope : National (30 School, 13 Provinces)
Impact :
12
Contribution to local community Build trust with local groups Positive atmosphere
TOYOTA MOTOR MANUFACTURING INDONESIA
3.1 Cooperation with Society 3.2 Atmospheric quality 3.3 Substance of Concern (SoC) 3.4 Energy / Global Warming
Sunlight
Photochemical smog Suspended particulate matter (SPM)
Process
Recovery Thinner 2007
Respiratory illnesses
(Impact of VOC)
Painting Process
2006
2. CLEAR ROBOT
70
60
59.45
60
55
Target 50
50
Major Activity
3.1 Cooperation with Society 3.2 Atmospheric quality 3.3 Substance of Concern (SoC) 3.4 Energy / Global Warming
Eliminate SoC in Part : Lead (Pb), Cadmium (Cd), Mercury (Hg), Hexavalent Cromium (Cr6+)
Part Example : Bracket Exhaust Tail
CR 6+ CR 6+
Avanza
20 parts
On Progress
Innova Fortuner
3.1 Cooperation with Society 3.2 Atmospheric quality 3.3 Substance of Concern (SoC) 3.4 Energy / Global Warming
B1
Internal Logistic Internal Logistic
B2
CO2 Generated
Ton CO2/Unit
0.6 0.5 0.4 0.3 0.2 Replacement of Diesel Oil with Natural Gas
CO2 reduction : 274 ton CO2 / Month Total Invest :Rp. 11.5 Billion Cost reduction : Rp. 1,4 Billion/Month
06
07
08 Year
09
10
B1
Internal Logistic Internal Logistic
B2
TMMIN
CO2
CO2
PRODUCTION LINE
Volume
(Stock, Space)
Supplier
Store
REDUCE VOLUME & REDUCE VOLUME & LEAD TIME LEAD TIME
COST COST REDUCTION REDUCTION CO2 CO2 REDUCTION REDUCTION
Time
TOYOTA MOTOR MANUFACTURING INDONESIA
AFTER
M A C H IN IN G
FORKLIFT SPACE : :2,154 m2 FORKLIFT SPACE 2,154 m2 FORKLIFT : :33Units FORKLIFT Units COST/DAY : :Rp. 216,000 COST/DAY Rp. 216,000 CO2 2: :690 Kg/Day CO 690 Kg/Day
CAM SHAFT M A C H IN IN G L IN E M A C H IN IN G C Y L IN D E R B L O C K L IN E FINISH GOOD ENGINE
C Y L IN D E R H E A D M A C H IN IN G L IN E
FORKLIFT SPACE : :1,820 m2 FORKLIFT SPACE 1,820 m2 FORKLIFT : :22Units FORKLIFT Units COST/DAY : :Rp. 144,000 COST/DAY Rp. 144,000 CO2 2: :460 Kg/Day CO 460 Kg/Day
CAM SHAFT M A C H I N I N G L IN E FINISH GOOD ENGINE C Y L IN D E R B L O C K L IN E
C Y L IN D E R H E A D M A C H I N I N G L I N E
DELIVERY KARAWANG
DELIVERY KARAWANG
BP
RECEIVING CHECK RECEIVING CHECK
BP
RECEIVING CHECK RECEIVING CHECK
BP
PACKING AREA PALLET SAFETY STOCK PALLET SAFETY STOCK MACHINING PART MACHINING PART
BP
PACKING AREA PALLET SAFETY STOCK PALLET SAFETY STOCK MACHINING PARTPART MACHINING
RECEIVING 1 F
RECEIVING CHECK RECEIVING CHECK
RECEIVING 1 F
RECEIVING CHECK RECEIVING CHECK
BP
BP
BP
BP
B B
BP
BP
BP
BP
B B
RECEIVING CHECK
RECEIVING CHECK
RECEIVING CHECK
RECEIVING CHECK
EMPTY STORE
EMPTY STORE
UNBOXING AREA
ASSY LINE TR
EMPTY STORE
RECEIVING 1 E
RECEIVING CHECK RECEIVING CHECK
UNBOXING AREA
EMPTY STORE
RECEIVING 1 E
RECEIVING CHECK RECEIVING CHECK
OVER FLOW
FREE LOCATION RACK
TEST BENCH TR
B
TEST BENCH TR
WAITING LANE
BP
AREA TRAINNING CENTER
ASSY LINE TR
OVER FLOW
FREE LOCATION RACK
WAITING LANE
FREE LOCATION RACK
BP
BP
BP
1 2
1 2
A A A
A A
J040 J076 J011 J023 M18C M18B M18A J020 J040 J076 J011 J023 M18C M18B M18A J020
PC STORE AREA
P1B P1B 15 14
OK M
M M 010 009
J016 M J016
6 7 76
B
KANBAN ROOM
KANBAN ROOM OASIS LOGISTIC TR
J040 J076 J011 J023 M18C M18B M18A J020 P1B P1B J040 J076PC STORE AREA M18A J011 J023 M18C M18B
15
J020
14
OK M
M M 010 009
J016 M J016
6 7 76
B
KANBAN ROOM
KANBAN ROOM OASIS LOGISTIC TR
PC STORE AREA
0051 O K M
PC STORE AREA
0051 O K M
8
START
8
START
9
P3A 27 P3A 26 P3A 25 P3A 24 P3A 23 P3A 22 P3A 21
9
P3A 27 P3A 26 P3A 25 P3A 24 P3A 23 P3A 22 P3A 21
P2A 16
P2A 15
P2A 14
P2A 13
P1A
P1A 10
P1A
9
11
PC STORE6 AREA 8 7 5
P1A
P1A
P1A
P1A
P1A 4
P1A 3
P1A 2
P1A 1
10 11
PC STORE AREA17 20 19 18
P2A
P2A
P2A
P2A
P2A
P2A 15
P2A 14
P2A
13
P1A
11
P1A 10
P1A 9
16
PC STORE6 AREA 8 7 5
P1A
P1A
P1A
P1A
P1A
4
P1A 3
P1A 2
P1A
1
10 11
OASIS ASSY TR
OASIS ASSY TR
START
12
START
12
Remarks : = Area Forklift
Remarks :
= Area Forklift
1) Productivity : Space Reduction for Forklift Operation : 334 m2 Forklift Reduction : 1 Unit 2) Safety : Reduce potential forklift (car) accident 3) Environment : CO2 Reduction : 230 Kg/Day 4) Cost : Reduction : Rp. 72,000/Day TOYOTA MOTOR MANUFACTURING INDONESIA
B1
Internal Logistic Internal Logistic
B2
B2. a. CO2 Reduction in External Logistic Activities TMMINs Logistics Supply Chain
B.2a
CO2
Volume
Importer
CO2 CO2
Tact Time :
Main Distributor
BASIC THINKING
Volume & L/T
Machine Machine
by 4 M Analysis
(Man, Machine, Material, Method)
by 4 M Analysis
(Man, Machine, Material, Method)
REDUCE VOLUME REDUCE VOLUME
(Truck Efficiency, Lot) (Truck Efficiency, Lot)
(Waiting time, Stagnant time, etc) (Waiting time, Stagnant time, etc)
Time
CIBITUNG/CIKARANG BEKASI
TMMIN
TANGERANG
KARAWANG/CIKAMPEK
BOGOR
2
= TMMIN Direct Supplier = TMMIN Milkrun Supplier TOYOTA MOTOR MANUFACTURING INDONESIA
1,128 Km/day
42,560 41,433
TMMIN
Karawang Plant
Cikarang
TMMIN
Karawang Plant 46 Km
41600
40800
Before
10400 Fuel Reduction
After
6 Delivery/Day, 190Km
Empty Space
2 Delivery/Day, 79Km
9600
262 L/day
9,613
Before After
Empty Space
28
68O Kg/day
25.9 25.2
Volume
Importer
BASIC THINKING
Volume & L/T
Machine Machine
by 4 M Analysis
(Man, Machine, Material, Method)
by 4 M Analysis
(Man, Machine, Material, Method)
REDUCE VOLUME REDUCE VOLUME
(Truck Efficiency, Lot) (Truck Efficiency, Lot)
(Waiting time, Stagnant time, etc) (Waiting time, Stagnant time, etc)
Time
Time
94 %
TMMIN Packing
Importer
TMMIN Packing
92%
Importer
90% 88%
66 Container/Day
54 Container/Day
8 6%
86% 84%
0 82%
B efore
A fter
EMPTY SPACE
NO EMPTY SPACE
NUMBER 100
80 60 40 20 0
OF CONTAINER
20 Cont./day
Before
After
Trucking :
3150 Kg/Day
Shipping (130 Ton/Cont):
674,700 Kg/Day
2 TOYOTA MOTOR MANUFACTURING INDONESIA
4. Conclusion
1. Environment conservation is important to be done to save the earth & as corporate social responsibility (CSR) 2. Environment management activities aligned with company goal to reduce cost and increase efficiency 3. To achieve cost reduction & CO2 reduction in manufacturing and logistic activities, it will maximize achievement of corporate competitiveness