Aisin AW is working to design production processes with the goal of achieving innovative manufacturing.
We are exploring the possibilities for techniques, equipment, production systems, and quality through a "three-in-one" organization consisting of design and development, manufacturing technology, and production divisions. Through this approach we seek to apply the results of the research and development of innovative technologies to improving the environment.
The Monozukuri Center provides a place for the pursuit of activities that move beyond divisional boundaries and conventional thinking. The facility is increasing the speed of innovation in manufacturing by grouping teams of professionals to address and explore various manufacturing research themes.
Innovative Manufacturing Framework
Considering environmental conservation as our mission, the Production System & Logistics Planning Department is working to achieve environmentally friendly distribution.
This section describes our efforts to reduce CO2 emissions and the use of packaging materials in product distribution.
Initiatives to Reduce CO2 Emissions
We have been working to reduce CO2 emissions from distribution operations, mainly by reducing the number of trucks and trips. This fiscal year, in addition to steadily implementing ongoing efforts across the organization, we launched a new initiative.
As a common initiative of the AISIN Group, we introduced full trailers for transporting and delivering products to customers in the Kanagawa area. As a result, the transport volume per trip increased by 40% and the number of vehicles and trips per day decreased by 40%. Further, it became possible to flexibly respond to fluctuations in load volumes by decoupling towed vehicles.
Through this initiative, CO2 emissions from distribution is expected to decrease by 139 tons* per year, for this fiscal year.
*Equivalent to the CO2 emissions generated from 175 round trips by passenger car between the northern tip of Hokkaido and the southern tip of Kyushu
Transport by 15-ton trucks
Transport by full trailers
Initiatives to Reduce Packaging Material Use
We have been making efforts to reduce the use of packaging materials from the 3R perspective (reuse, reduce, recycle). Last year, we worked to reduce the use of anti-rust packaging materials for products shipped overseas.
In the past, when delivering products to customers in areas with high temperature and humidity, in addition to applying anti-rust agent (anti-rust oil) to products, on customer request we packaged products individually in an anti-rust pouch to improve rust prevention. Last year we developed a new anti-rust agent. This agent has superior anti-rust effect, eliminating the need for individual packaging in anti-rust pouches even for those customers. The new anti-rust agent has also enabled us to switch from individual packaging to bulk packaging using anti-dust sheets.
Through this new packaging approach, the use of packaging materials is expected to decrease by 122 tons per year, this fiscal year.
We will continue pursuing environmentally friendly distribution by actively taking on new challenges for continuous improvement.
Individual packaging in anti-rust pouches
Bulk packaging with anti-dust sheets
What is Remanufacturing?
In a word, it's the automatic transmission recycling business. Aisin AW provides recycled automatic transmissions at an inexpensive price point for use in repair and replacement of models already in service. The company is contributing to global environmental conservation through its remanufacturing program, reducing waste products and effectively using resources.
Three facilities-AWQUIS JAPAN (Aichi Prefecture), AW Transmission Engineering U.S.A., Inc. (North America), and the AW Europe Service Center (Europe) recover automatic transmissions from the market and disassemble and repair them, guaranteeing proper functionality.
Aisin AW's Commitment to Energy Efficiency
Our basic approach to energy consumption is focused on improving environmental performance, achieving greater cost effectiveness, and ensuring a stable energy supply. These three concepts add up to a balanced use of energy. Collectively we call this the "BEST MIX" of energy use. We also believe that it is important to precisely target energy delivery to reflect the locations, times, and quantities that characterize demand.
Aisin AW sees the prevention of global warming as consisting of the suppression of CO2 emissions by promoting energy conservation initiatives. The Energy Subcommittee lies at the center of the company's efforts in this regard, which reflect the internal slogan, "Protecting the global environment is a job for everyone." Aisin AW has come together to focus on energy conservation.
Reducing CO2 Emissions per Unit of Energy Used and Total CO2 Emissions
Reducing Waste Products and Encouraging Zero Emissions
The Waste and Recycling Subcommittee is responsible for setting waste reduction targets and determining the overall direction of related activities. As of 2005, we had achieved the first three waste reduction steps—reducing waste product processing by outside companies, eliminating landfilled waste, and reducing incinerated waste. Fluctuations in production volume have made it challenging to achieve the fourth step of reducing total waste product volume, but we have nonetheless achieved annual targets for the subsequent five years. We began the fifth step of reducing waste product volume per unit of production in 2011, and we will work to recycle waste plastic this year in an effort to achieve the associated targets.
Waste Reductions Activities
Reducing total emissions (waste products)
We have continued to work to reduce waste volume per unit of production (Step 6) since FY2016. We will determine specific reduction targets based on a consideration of production volume forecasts. Our specific approach, which will be shaped by the 3Rs, will include recycling waste oil for use as a raw material in the production of remanufactured fuel oil and as a fuel for incinerators.