Toyoda Gosei Co., Ltd. (Kiyosu City, Aichi Prefecture)
Chubu Electric Power's energy consultant responds promptly with "site and actual items". Chubu Electric Power strongly supports energy conservation and CO2 reduction at overseas production factories.
PROFILE
Toyoda Gosei Co., Ltd. was founded in 1949 and produces a wide variety of products centering on automobile parts using polymer technology of rubber and resin. With 64 group companies operating in 17 countries and regions around the world, they celebrated their 70th anniversary in 2019. Main products include weather strip products such as glass runs and opening trims; functional parts such as brake hoses and fuel filler pipes; interior and exterior parts such as radiator grills and console boxes; safety system products such as airbags, steering wheels; special products such as LED lights, air purifiers, semiconductor products, and e-rubber products.
PROJECT MEMBER
Toyoda Gosei
- Environment Department
- Deputy General Manager
- Kazuhiko Nagao
Toyoda Gosei
- Environment Department
- Environmental Promotion Section
- Hiroki Hattori
Toyoda Gosei
- Environment Department
- Environmental Promotion Section GL
- Tetsuhiro Ito
Toyoda Gosei
- Environment Department
- Environmental Promotion Section GL
- Takuya Suzuki
Chubu Electric Power
- Nagoya Sales Department
- Tohru Okimoto
Chubu Electric Power
- Nagoya Sales Department
- Tomohiro Iwata
Chubu Electric Power
- Nagoya Sales Department
- Kazuki Yoshizoe
Chubu Electric Power
- Nagoya Sales Department
- Masato Oishi
Promote Energy Conservation at Overseas Factories that Account for About 70% of CO2 Emission
Toyoda Gosei has formulated the “TG2050 Environmental Challenge” in 2016 and has set the goal of “Minimizing CO2 emission from factories” in order to accelerate the reduction of global CO2 emission toward the pursuit of sustainability. To achieve this goal, they are promoting various efforts, such as forming a specialized team "TG-ESCO (Note)" to improve utilities and production equipment from the viewpoint of energy saving, aiming for "Zero energy loss".
(Note) TG-ESCO:
TG-Energy Saving Collaborative Operations
Chubu Electric Power has proposed the operation improvement of industrial air compressors (compressors), air conditioners, boilers, cooling equipment, production processes, etc. at domestic production factories, and has achieved good results. Since 2015, we have started a new service called “Overseas Energy Conservation Support Service,” which conducts field survey and data measurement of overseas factories and proposes energy conservation.
This time, we received a consulting service request from Toyoda Gosei.
"About 30 overseas factories of Toyoda Gosei Group account for approximately 70% of CO2 emission. In order to promote global CO2 reduction, the energy saving activities cultivated in Japan should be further spread to overseas factories. It is necessary to foster a corporate culture that is systematic, efficient, and self-sustaining. Therefore, we would like to ask for the support of Chubu Electric Power that has extensive experience in this field." (Toyoda Gosei)
Although many of the overseas production factories have the same production equipment as in Japan, energy-saving strategies are different, and the number of Japanese staff stationed there is small. The urgent issue is how to implement the CO2 reduction measures tailored to the circumstances of each area.
Proposal of Operational Improvement Measures that can be Executed Immediately Based on Measurement Data at the Site
Chubu Electric Power's energy conservation support service method is basically the same as in Japan. We measure power consumption data and operating time of utility equipment that supplies energy to the manufacturing site, and based on the obtained values, we will find out waste and leakage by matching the characteristics of the equipment and the production process, and show detailed solutions that is suitable for the site in order to optimize operation.
In the case of overseas factories, it is indispensable to accurately indicate the points to be improved within a limited period of visiting time and have the local staff understand "why it should be improved" and "how to implement solutions"... Therefore, we will ask for necessary data such as production lines and equipment drawings in advance, and will coordinate with local staff.
"There are various circumstances depending on the country/region, but under any situation, we have a mission to increase the effectiveness of energy saving in a short period of time. We are aiming to reduce energy consumption by 5-10% in the entire factory by steadily implementing improvement measures. This goal is quite challenging and gives us a lot of pressure, but when the result exceeds the target, it has become the real pleasure of energy conservation consultant and a great reward for us." (Chubu Electric Power)
Flow of Overseas Energy Conservation Support Service (Image)
Energy Conservation Support Service With Short-Term Concentration in Different Countries and Energy Situations
Toyoda Gosei divides the world into four regions (Japan, Americas, Asia, Europe and Africa) and develops production activities in line with the actual conditions of the region, centering on the flagship factories. When conducting energy conservation activities overseas, Toyoda Gosei selected its main factory or a factory that has large energy consumption, and after one month of preparation, we, project team started the service in China.
[China] Identify the Location of the Air Leakage and Mark it for Immediate Implementation
Firstly, we worked on "Toyoda Gosei (Foshan)" in Foshan, Guangdong.
In many cases overseas, the compressor set pressure is high, and so is the factory in Foshan. We confirmed the actual work on site and reduced the pressure to an appropriate level. In addition, a number tag was attached to the air leakage location so that it can be seen at a glance, and the location and the repair method were shown in the equipment layout diagram with a photograph so that it can be confirmed even after the inspection. We tried to explain the principles and methods of energy reduction to the people on site so that they could understand them. By setting up such awareness-raising activities, it will help to improve awareness among local staff.
"Chubu Electric Power is not only helping us to indicate the improvement points, but also strongly supporting until implementing and showing results. Everyone can check the air leakage places, where it has been repaired, and where it has not, which results in a higher implementation rate. We will expand this method globally.” (Toyoda Gosei, Mr. Ito)
“The local staff who accompanied me were also impressed that the method of Chubu Electric Power is specific and easy to implement. It seems that the number tag for air leakage checking was new for them, and the Shanghai headquarters started the inspection in another factories in the area. It is now possible to do it with only two female staff members” (Toyoda Gosei, Mr. Hattori (stationed in China in 2015)).
Measurement/problem extraction/proposal/discussion of improvement measures at the Foshan site
“We also asked for energy conservation support service in our factories in Thailand, and the local staff who received guidance at that time now became energy conservation education instructors for the Toyota Group in Thailand.” (Toyoda Gosei, Mr. Hattori)
"We had to perform factory surveys not only on weekdays but also on non-working days on Saturdays and Sundays depending on the equipment, but I really appreciate Chubu Electric Power for investigating and responding even during non-working days. (Toyoda Gosei, Mr. Nagao)
[Czech Republic] Proposal for Measures to Reduce CO2 Emission four Times of the Target by Identifying Improvements in the Production Process
“Toyoda Gosei Czech” located in the Northwestern part of the Czech Republic is a pioneer of Japanese companies expanding into the country. While the environment at this site and energy conservation activities were maintained at a high level, the target for reducing CO2 emission was set at 1.1% per year, the same as at other sites. Chubu Electric Power divided four factory buildings into two teams with a four-member structure, investigated and identified the issues, and proposed 4% annual reduction measure which is equivalent to about four times of the target.
"We visited the factory in the morning and asked the local staff about necessary data, and we had quick response in the afternoon so we were able to analyze with received data. We were worried if we can provide effective improvements for equipment that is already well maintained, but with the full cooperation of the local staff, we were able to make a proposal that exceeded our expectations." (Chubu Electric Power)
"After that, I explained the report of Chubu Electric Power to the top management board of the local company, and they were grateful for the detailed research and specific suggestions for improvement." (Mr. Nagao, Toyoda Gosei)
[United States] Point Out Improvement Points Based on Actual Data on Site, Raise Awareness of Energy Saving, and Execute
In the United States, we worked on "TG Kentucky" located in Kentucky. The electricity rate in the United States is low, and energy conservation awareness is not as high as in Japan. Furthermore, the local staff have thought that "everything is perfect because we have introduced the compressor unit control system".
Under these circumstances, Chubu Electric Power took real-time data with measurement devices and made graph of the energy consumption to show improvement points. The explanation by using actual data at that factory but not from other factories results in deeper understanding and higher satisfaction.
"In case of overseas factories, we can't make progress of improvement unless we have agreement from the people on site. We are striving to devise ways of showing data, create graphs summarizing points, and make clear presentations by utilizing the knowledge that we have accumulated. (Chubu Electric Power)
“In the beginning, I was skeptical whether they could check out a lot of equipment in a short stay of 4 days, pick out improvement points and come up with countermeasures. However, when I actually came to Kentucky, Chubu Electric Power were communicating smoothly with local staff, quickly measured the listed utility equipment, found improvable areas, and even gave a presentation. I was surprised at the management ability.” (Toyoda Gosei, Mr. Suzuki (stationed in the US in 2018))
Proposal of Energy Reduction Measures at Each Site
Chubu Electric Power has provided consulting services to China, Thailand, the Czech Republic, and the United States, and proposed energy reduction measures of 3-8% at each production site.
Supporting Global Sustainability Through Both Operational Improvement and Capital Investment
Since December 2019, Toyoda Gosei has added the directors of overseas offices as members of the "Environmental Committee" to strengthen energy conservation measures at overseas production sites.
"In Japan, the manufacturing department and the environment department are working together in developing "TG-ESCO activities" in order to find ways that can improve energy conservation, but I think it is necessary to send a team like that to overseas factories. It would be very helpful if Chubu Electric Power that is professional in energy could support us from now on.” (Toyoda Gosei, Mr. Ito)
In order to achieve the 2050 goal of “minimizing CO2 emission from factories,” the use of renewable energy is also an essential requirement. This is the most worrisome subject, and we hope to have advice from Chubu Electric Power in terms of clean energy supply as well." (Mr. Nagao, Toyoda Gosei)
"Achieving the first step towards "minimizing CO2 emission" "Zero energy loss" requires various measures. By utilizing the experience and research results, we are developing "Evolution of energy visualization" and "solutions utilizing IoT" etc. By using such technology, we not only provide "operational improvement" to optimize equipment operation, but also "equipment investment" that involves management decisions, and ESCO activities in Japan and overseas. We also offer useful suggestions for efficient use of clean energy." (Chubu Electric Power)
In our overseas energy conservation support service, we will prepare a report after conducting field surveys and discussions. Furthermore, we also can go back to the site as after-sales follow-up, check the improvement status, educate local staff, and create a medium-to-long-term activity plan. We will continue to further refine our energy consulting knowledge and contribute to the sustainability of global companies based on the achievements of 31 overseas factories of 23 companies (as of April 2020).
- Introduction Example