Eco-efficiency of operations

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Coming from Japan, the concept of ecofactory has as its main pillar the Morizukuri Project, a Japanese word meaning "to create a forest." In addition to production aspects, plants built or adapted within this concept adopt world-class eco-efficiency goals, establishing a series of environmental improvements in energy, emissions, and waste, and combine cutting-edge technology and efficiency and productivity kaizens - all without impacting the quality of life of the residents of the municipality and neighboring cities or generating risk of any environmental contamination.

The goal for the Toyota Motor Corporation is to adapt or open 100% of its production units around the world based on this model. In Brazil, the first ecofactory plant was the Sorocaba plant, built in 2012. The Porto Feliz unit was designed as an ecofactory: the use of inorganic sand in its construction, the compact production system, and the use of solar energy to illuminate outside areas are just a few of the highlights.

Energy

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Reduced energy consumption in operations and the use of renewable resources are two of the main focuses of the TDB units. In the 2017/2018 fiscal year, there was an increase in total electricity consumption due to the start-up of the Porto Feliz engine plant and the expansion of the Sorocaba plant. Natural gas consumption also increased due to the start-up of the Porto Feliz engine plant, which uses gas to melt aluminum ingots and build engine blocks and motor heads.


Energy consumption within the organization
Unit 2016/2017 2017/2018 2018/2019
Energy consumption within the organization GJ 197,533.43 208,723.93 221.9
LPG GJ 107,752.95 2,143.64* 2.07
Electricity consumption GJ 276,659.00 322,852.49 330.9

* Indaiatuba's LPG consumption began to be recorded in the logistics operation.


The goals for reduction in energy consumption are established in two areas: total consumption, and consumption intensity (GJ/vehicle). In this way, Toyota uses a methodology that ensures compliance with the commitment to reduce emissions annually. Energy intensity in the last fiscal year was 1.59 GJ/vehicle. This index is higher compared to the previous period due to the start of Porto Feliz operations.


A Toyota Motor Corporation tem como meta readequar ou inaugurar 100% de suas unidades de produção ao redor do mundo com base no modelo ecofactory
Energy intensity
Unit 2016/2017 2017/2018 2018/2019
Natural Gas GJ/ vehicle 1.12 1.03 0.98
LPG GJ/ vehicle 0.61 0.01* 0.01
Electricity consumption GJ/ vehicle 1.56 1.59 1.56

* Indaiatuba's LPG consumption began to be recorded in the logistics operation.

The activities to reduce energy consumption were well developed at the Indaiatuba plant, following the example of the Sorocaba plant in 2017. Improvements implemented were:

• Shutting off the chiller in case of low temperature in the air house (the same kaizen implemented at Sorocaba, adapted at Indaiatuba).

• Optimization of equipment operation (chiller) by the enthalpy curve (also the same kaizen implemented at Sorocaba, adapted at Indaiatuba).

• Reduction in gas consumption in the ED oven.

• Replacement of 100% fluorescent lamps with LED lamps, activity that was also replicated at the Sorocaba plant.


Reduced energy consumption
Unidade 2016/2017 2017/2018 2018/2019
Improvements in energy conservation and efficiency GJ 23,137.00 14,671.03 4,773.14
Redesign of processes GJ 290.00 462.60 323.22
Modernization of equipment GJ 1,866.00 2,171.34 2,240.01
Changes in employee behavior GJ 1.205,00 205,58 8,84
Total GJ 26,498.00 17,510.55 6,272.87
Water <303-1>

Toyota do Brasil's commitment is to reduce water consumption in the production of its vehicles and components by at least 1% per year. This basic goal is developed across organization layer by layer, so that each section knows exactly how much it is contributing to the goal, stimulating the practice of continuous improvement by the employees.



Total volume of water withdrawn, broken down by sources
Unidade 2016/2017 2017/2018 2018/2019
Groundwater 158,307.00 202,713.06 218,818.00
Supply from public or private water utilities 123,319.00 119,616.93 96,165.00
Total water consumption 281,626.00 322,328.99 314,983,00

As with energy consumption, Toyota also monitors water consumption per vehicle produced (m3/ vehicle). Last fiscal year this rate remained stable, even with the start of operations of the new engine factory (Porto Feliz).

Water consumption in plants (m3/ unit)
2016/2017 2017/2018 2018/2019
São Bernardo do Campo 0.18 0.12 0.12
Indaiatuba 1.63 1.42 1.37
Sorocaba 1.21 1.15 1.09
Porto Feliz Not operational 0.21 0.20
Water consumption (m3/ Vehicle Produced) Consumo de água (m³/ Veículo Produzido)

During the fiscal year, several improvement projects were implemented, such as the modernization of the Motoring Bench System in Porto Feliz, with a reduction of 34 m³/year in the volume of water used for engine flow tests. At the São Bernardo do Campo plant, the installation of the water reuse system began treating the effluents generated at the restaurant for industrial use in the cooling tower of the forging plant for exports.

The Sorocaba plant also implemented several projects, such as the reduction of water consumption in the Shower Test Audit process (6.87 m³/year), urinals (3.48 m³/year), and flushing (3,007.06 m³/year), as well as the application of reclaimed water in the preparation of polymers (2,700 m³/year).



Em todas as plantas, o efluente gerado no processo produtivo é direcionado para a Estação de Tratamento de Efluentes (ETE).

Waste and effluents

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In all plants, effluents generated in the production process are sent to the Effluent Treatment Station (ETE), where they undergo treatment through a physical-chemical process, and are then returned to the public network within the defined parameters. These parameters are monitored monthly by a qualified laboratory.



Effluents generated in processes
Unit 2016/2017 2017/2018 2018/2019
Indaiatuba 93,175.00 86,513.00 76,354.00
São Bernardo do Campo 6,794.00 6,815.00 7,378.00
Sorocaba 77,940.00 95,401.00 106,509.00
Porto Feliz Not operational 207.11 8,902.00
Total 177,909.00 188,936.11 199.143

Waste generated at Toyota do Brasil is classified according to NBR 10.004/2004 of the ABNT, due to the potential risks to the environment and public health, ensuring that its management is carried out properly and in compliance with the applicable legal requirements. Based on the results of the last fiscal year (2016/2017), the company determined a 1% reduction in waste generation for 2017/2018.

Generation and collection data are monitored on a daily basis, and for indices that are outside the established targets, a case study is carried out to take corrective measures.

The targets are established individually for each production sector, based on data from the previous year in a more restrictive manner, aiming toward continuous improvement and achievement of results.



Os dados de geração e coleta são monitorados diariamente.

Waste generated at plants (kg/ unit)

2016/2017 2017/2018 2018/2019
São Bernardo do Campo 1.43 1.13 1.11
Indaiatuba 9.35 7.72 7.16
Sorocaba 6.29 5.84 5.72
Porto Feliz Not operational 1.93 1.92


Waste generated (kg/ Vehicle Produced)





VOC Emissions

The emissions indicator for volatile organic compounds is applicable to vehicle painting processes. For Toyota do Brasil, the Indaiatuba and Sorocaba plants are monitored to reduce emissions by 1% per year, measured in g/sqm. The Indaiatuba plant was recognized in 2017 by the parent company as Best In Class among the subsidiaries that use solvent-based paint on vehicles. The efforts of employees in Indaiatuba's painting process also earned the award for Best Environmental Kaizen (Global Eco Platinum Award), for the set of improvements implemented.

2016/2017 2017/2018 2018/2019
São Bernardo do Campo n/a n/a n/a
Indaiatuba 32.87 32.21 31.05
Sorocaba 12.15 12.02 11.73
Porto Feliz n/a n/a n/a
VOC Emissions (g/sqm of vehicle area) Emissão de VOC (g/m² de área do veículo)