1. TMCA and the EEO Applying Toyota Business Practices to Energy Efficiency

2. Toyota Australia Overview
REGIONAL OFFICES =
Townsville
Brisbane
Sydney
Melbourne
Adelaide
Darwin
WA Distributor
MELBOURNE
Port Melbourne
Corporate Head Quarters
(CHQ)
Altona Manufacturing Plant
Engine, Foundry, Press, Paint and Assembly
SYDNEY
Sales & Marketing
LOCAL SUPPLIERS
1,794
Purchase value: A$1.65 billion
DEALERS
Toyota: 210, Lexus: 19
Employees: 12,615
TMCA EMPLOYEES
Total = 4,184
Nationalities = 60+

3. Toyota is Australia’s biggest manufacturer of cars

4. In 2012 nearly 100,000 Camry, Camry Hybrid and Aurion left our Altona factory.

5. Toyota considers Sustainability in all parts of our operation

6. Carbon Foot Print of a Camry
Parts Manufacture (Suppliers) = 2.64 tonne/car
Embedded energy in Materials = 5.98 tonne/car
Vehicle Manufacture = 1.50 tonne/car
Offices &
Warehouses
0.13 tonne
Per vehicle
A/c gas
= 0.65
tonne
Lifetime use of vehicle = 44 tonne/car
Parts and Vehicle Logistics = tonne/car
Sales Activities = 0.21 tonne/car

7. EEO as part of the response
The EEO is a part of Toyota Australia’s response strategy to limit the impacts of the Clean Energy Future Scheme
The EEO is used as a management tool in the overall response which also includes:
Toyota’s Guiding Principles
The Toyota Earth Charter
The TMAP Regional Action Plan
Toyota Australia’s Environmental Action Plan
Annual Environmental KPI’s

8. TMCA Activity – “Axe the Tax”
To encourage Energy Efficiency in manufacturing, TMCA had an ‘Axe the Tax’ campaign in 2012 to:
Implement Actions to reduce the impact of the CEFS
Offset additional cost through identified savings
Encourage all Shops to put forward Energy Efficiency Initiatives

9. Challenges
The key challenge with using the EEO processes for Toyota Australia is turning a legislative requirement into a useful business tool suitable to our industry.
How do we reconcile:
Data vs Information
Legislative vs Company requirements (i.e Payback criteria)
Energy vs Carbon
Toyota systems vs Government systems

10. EEO and TEMS TMCA integrates EEO through our EMS
Each shop has a multi disciplinary TEMS team
Each TEMS team has access to support from engineering and Corporate groups
Each TEMS team is tasked with finding and implementing improvement ideas

11. The PDCA Cycle
TMCA uses the PDCA process to implement energy efficiency projects
Plan – The TEMS teams look at identifying new projects and gather all relevant data (including baselines etc).
Do – The projects are assessed, approved and implemented (taking account of EEO requirements)
Check – the performance of the project is measured against expectation (daily, weekly, monthly)
Act – The project is integrated, standardised and shared

12. Case Study: VSD Drives - Background
Before Kaizen:
The supply & exhaust fans in cavity wax are connected in direct online configuration
They have a current 6 times the motor rated current at start-up
This results in unnecessary energy being consumed.
During Production time, the fans are running at full capacity and are being left on during non production time thus using excess energy (Gas & Electricity).
Maintenance regularly have to change and repair motor belts & pulley.
The conditions of these booths have changed as they are now dry booths.

13. Case Study: VSD Drives - Activity
Activity – Install Variable Speed Drives:
Undertake detailed analysis of current power consumption
Install Inverter to be able to control speed of Fans
Consult with all stakeholders regarding
Quality concerns
Maintenance issues
OH&S concerns

14. Case Study: VSD Drives - Results
After Kaizen – Supply Fan:
Reduced frequency from 50 Hz to 45 Hz and then 40 Hz
Power reduction from 50kW to 28 kW
50HZ
45HZ
40HZ

15. Case Study: VSD Drives - Results
After Kaizen – 2 X Exhaust Fan:
Reduced frequency from 50 Hz to 45 Hz and then 40 Hz
Power reduction from 17 kW to 9 kW
50HZ
45HZ
40HZ

16. Case Study: VSD Drives - Results
After Kaizen:
Power savings: $23,294
Gas savings: $28,071 (reduced air flow)
Maintenance: $2,128 (no need to repair the belts & pulleys on a regular basis)
Equipment parts cost savings: $3,950 (motors are now ramped up slowly resulting in less stress on belts and pulleys)
Total savings: $57,443 per year
Implementation cost: $34,700
Pay back 7 Months

17. Case Study: VSD Drives - Yokoten
Yokoten and Next steps:
Roll out activity to other fan motors across the Paint Shop
Identify potential applications in other shops such as:
Black Out Spray Booth Paint Shop
Torit exhaust system in Body Shop
Weld exhaust system in Press Shop
Emission test Laboratory ventilation system

18. Case Study: VSD Drives – Recognition
TMCA acknowledges that the key knowledge about process improvements sits in the TEMS work teams and we hold an annual awards process to recognise their efforts.
In 2013 there were 10 teams competing in the annual TEMS awards
The combined savings of the projects put forward exceeded $1.4 million per year
The 2013 Winner and submission for the Global Eco Award was the Paint Shop Maintenance VSD Drive project