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August 17, 2012

August 17, 2012. Energy Huntsville Forum. 1. CAPTIN 1985. TMMC 2 2008. TMMC 1988. SIA 2007. TEMA 1996. TMMWV 1998. TMMI 1999. BODINE 1990. TABC 1971. TMMK 1988. BODINE 2005. TMMAL 2003. TMMBC 2004. TMMMS 2011. TMMTX 2006. $21+ Billion Invested 40,000 Direct Employees.

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August 17, 2012

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  1. August 17, 2012 Energy Huntsville Forum 1

  2. CAPTIN 1985 TMMC 2 2008 TMMC 1988 SIA 2007 TEMA 1996 TMMWV 1998 TMMI 1999 BODINE 1990 TABC 1971 TMMK 1988 BODINE 2005 TMMAL 2003 TMMBC 2004 TMMMS 2011 TMMTX 2006 $21+ Billion Invested 40,000 Direct Employees Toyota Manufacturing in North America Vehicle Plants - 7 Unit Plants - 5 Engine Plants - 2 Regional HQ 2

  3. TMMAL Overview – Company Profile Foundation: June 1, 2001 Investment: $700 million (by Spring 2014) Location: Huntsville, AL Toyota Property Line NEW 3.5L V-6 Plant Size: Land 200 acres Building 1.08 million sq ft 5.7L & 4.6L V-8 Employees: 1,150 (by Spring 2014) 4-Cyl 4.0L V-6 3

  4. What Makes Toyota Different? • Empower Team Members • What Gets Measured Gets Done • Never Stop Improving 4

  5. TMMAL Environmental Team What is the Environmental Team? • Provides support, guidance and standardization • Team Member-driven Environmental system/program • Follows annual calendar for activities, training and audits Who is on the Environmental Team? • Voluntary position • 2 per Group House – 1 per shift • Serve at least one year, many serve longer if trained as Internal Environmental Auditor 5

  6. Regular Environmental Activities 6

  7. Daily Process Checks • Production Team Members check their process daily at start and end of shift • Report any issues or concerns for compliance or risk • Enables management, Environmental Team Members to quickly address issues and implement countermeasures Right: Mist Collector Machining Process Below: Daily Checksheet 7

  8. Kamishibai Checks • Use card system and board for audit tracking • Environmental Team completes weekly audit on all items in daily checks • Managing your process • Compliance and risk • Knowledge retention • Ensures production Team Members are completing daily checks accurately 8

  9. Team & Management Meetings • Monthly Team meeting to: • Share targets and results • Communicate new requirements • Highlight special events • Provide monthly status update to upper management, address any specific issues raised in Monthly Team Meeting 9

  10. Semiannual Environmental Audits • Specially-trained group of auditors within Environmental Team • Conduct semiannual audits to confirm system health. Look for: • Compliance and risk management • Training records and document control • Face-to-face interviews with randomly selected team members on environmental awareness topics • Auditors responsible for multiple areas in plant, but can’t audit own area 10

  11. Semiannual Kaizen Blitz KAIZEN– Continuous Small Improvement BLITZ– Hitting it from all directions in a concentrated effort! • Cross functional team focuses on improvements in specific environmental impact areas: • Energy • Water • Waste • Special Projects 11

  12. Semiannual Kaizen Blitz • Corporate offices provide target reduction percentage, TMMAL calculates identified savings for next year • Potential kaizens placed on following FY’s Environmental Management Plan • TMMAL currently working on items identified in FY12 12

  13. Semiannual Kaizen Blitz 13

  14. Semiannual Kaizen Blitz • Compressed Air Actuators13 valves not being • used in production areas • 63 hours/week • Estimated Annual Savings: • 283,500 kwh/year • $19,845 / year 14

  15. Semiannual Kaizen Blitz • Outdoor Lighting • Switch outside HPS lighting to UCD Lighting • Reduces energy usage by 70% • Total of 100 pole lights Old Cost = $23,993 Savings = $8,656 / yr Payback = 2.75 yrs Energy Reduction = 123,662 kwh/yr New 15

  16. Semiannual Kaizen Blitz 16

  17. Semiannual Kaizen Blitz • History • Average Summer monthly usage = 1,000,000 gallons • Average waste = 150,000 gallons 6/7 cycles • Projected • 70% of lost water will be saved with filter • 105,000 gallons will be put back in system 1/7 cycles Nano Filter 17

  18. Semiannual Kaizen Blitz 18

  19. Semiannual Kaizen Blitz • Covanta Go-and-See • Environmental Team Members visited Covanta site • Potential Items to be recycled: • Cardboard • Plastic • Paper • Parts • Dunnage • Target 50% of load diverted to recycle stream Driver left debris when leaving compactor 19

  20. Summary • Empower Your Team Members • What Gets Measured Gets Done • Never Stop Improving 20

  21. Any questions? 21

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