Challenge3

Plant Zero CO2 Emission Challenge

CO2 emissions under BAU

2001 2030 2050

Development and introduction of low CO2 production technologies and daily Kaizen activities" and "Renewable energy and hydrogen use" are keys to zero CO2 in 2050

Plant CO2 emissions ⇒ Aiming for zero in the long run

Reduced by low CO2-emitting production

technologies and daily Kaizen activities

Reduced by using renewable energy and hydrogen

2001 2020 2030

（ Index） 100

50

0 Present 2015

Initiatives for reduction by low CO2 production technologies and daily Kaizen activities

Reduction of CO2 emissions per vehicle at a new plant

Approx. 1/3

Aiming for reduction to approx. 1/2 by 2020, and to approx. 1/3 by 2030

Low CO2 production

technologies

Daily Kaizen activities

[Simplification and streamlining]

・thorough shortening of production process

・minimization of moving parts

・energy saving of moving parts

[Improvement of energy use efficiency]

・recovery of wasted energy

・storing of energy

・elimination of unnecessary/inconsistent/

unreasonable efforts

・unpowered/low-thrust operation energy

Painting

Casting

Machining

Machining

Entire process

Examples

Initiatives for reduction by low CO2 production technologies and daily Kaizen activities

Battery production

Machining

Casting

Body painting

CO2 emission ratio by production process

Parts painting

Other

Stamping

Body

Molding

Assembly

Plastic coating

Air conditioning

Parts

Thermal process

Forging

Approximately 60% of the total

In addition to body painting, casting, and machining, which are major contributors to CO2 emissions, battery production which will

grow in the future will be an important issue of technological development

Amount of CO2 emission by production process （FY2013）

Volume

▲50% CO2 reduction

▲30% CO2 reduction

▲10% Energy saving ⇒ CO2 reduction by 40%

Downsize equipment Harden sand mold at low temperature

Existing （2001）

Development （2020）

organic sand mold

harden at high

temperature

Existing

inorganic sand mold

harden at low

temperature

Development

Low CO2 production technology （Casting process）

Low CO2 production technology （Machining process）

The number of equipment

▲30% CO2

reduction

▲40%

Recovery of excess energy

▲10%

CO2 reduction

▲10%

Energy saving ⇒ CO2 reduction by more than 50%

Reduce the number of equipment by speeding processes Recover energy with no waste

Existing （2001）

Existing

Development

Development

Energy emission

Recovery of energy

Daily kaizen - initiatives for Karakuri mechanism

What is “Karakuri Kaizen” ?

Wisdom &

Ingenuity

Utilize for Production equipment

・unpowered ・low-thrust

Karakuri doll

Gravity (weight)

Magnetic force

cam

link balance

Differential action

gear

spring

Daily kaizen - initiatives for Karakuri mechanism

TPS Promotion Center “Studio of Karakuri ideas”

Karakuri group

training

On the job

training

(OJT)

Information

sharing

Field

training by

instructors

Toyota challenges the use of renewable energy and hydrogen energy

Renewable energy use Hydrogen energy use

Direct use of solar power generation

and wind-power generation

Power generation from CO2-free hydrogen

Use of liquid hydrogen evaporation heat air conditioning

Use hydrogen combustion in the production process

Renewable energy

Liquid hydrogen tank

Hydrogen power generation etc.

CO2-free hydrogen

Cold heat & combustion

electricity electricity

Filling

Initiatives at new plants for the Zero CO2 Challenge

Reduce production energy use with the latest innovative

lowCO2 Technology and promote using of renewable energy

Reduce more

than 40%

New plant in Mexico

CO2 emissions

2001 Around 2020

Steady adoption of the

latest innovative

low CO2 technologies

Proactively use

renewable energy

with consideration

for local

characteristics

and economic

efficiency

Renewable energy use

As the first process, wind power generation will be introduced in domestic plants by around

2020, for zero CO2 in the FCV production line

Local (Business and residential)

Motomachi Proof Test Share electricity

& heat

Purchase from renewable energy operators

・Wind power

・Solar power

・Biomass

・Geothermal, hydro power, etc.

Toyota de Brazil in Brazil will be the first plant to start the use of100% renewable energy from

2015

Power transmission infrastructure

On-site renewable energy

Improve amount per unit

・Accelerate low CO2 innovative technology

・Daily Kaizen

・Energy conversion （Steam, airless）

Toyota Group In-house, and on the premises

Production plants & office buildings

Power transmission Power company

Hydrogen use Image of hydrogen production supply and use technologies aimed at 2020

A proof test of hydrogen technology will be launched at the FCV production line in 2020

Launch technological development and demonstration by

Toyota Group companies

Low CO2 hydrogen production

・Hydrogen byproducts

・Fossil fuels

・Reformed hydrogen

Liquid hydrogen tank

Vaporization equipment

Pressurization equip. FCV filling

Hydrogen power generation etc.

FCV Development & evaluation facility

gas burner

air conditioning equipment

Liquid

Hydrogen production with

surplus electricity

CO2-free hydrogen production

Heat treatment furnace etc.

Review of hydrogen use technology ・Thermal catalyst use ・Oxidation use, etc.

Heat use Gas mixture burning

Cold heat use For air conditioning, etc

Electricity use ・Ultra efficient power generation ・Hydrogen power generation

H2 Gas Cold heat

Hot H2 Gas

Liquid hydrogen truck

Liquid

electricity

Plant use of hydrogen Hydrogen production & supply

More efficient Compressed

hydrogen production

Gas (CH4 etc.)

Spread to new and existing plants worldwide

Aiming to spread zero CO2 clean processes to all plants worldwide

Plant Zero CO2 Emission Challenge

Thoroughly reduce the amount of energy use Use of renewable energy & hydrogen ＋

First plant in Japan First plant in Brasil

再生可能エネルギーとCO2フリー水素活用による 人と自然が共生する未来づくり