Toyota Kirloskar Motor Takes Giant Strides Towards Achieving Zero Carbon Emission Manufacturing Facility

Guided by Toyota’s ‘Global Environmental Challenge’ 2050 in line with the United Nations Sustainable Development Goals, till January ‘19 [in FY 2018-19] - Toyota Kirloskar Motor (TKM) successfully sourced 87% of electricity from renewable source of energy for its operations in Bidadi facility.

With key focus on its energy challenge, Toyota has been swiftly moving from non-renewable to renewable sources of energy across its business operations, as electricity consumption being one of the major sources of energy in manufacturing sector. TKM has been able to prove its eco commitment with continuous improvements in remarkable green energy sourcing trends year- on-year. Toyota Kirloskar Motor’s vision, philosophy and guidelines are true reflections of its commitment for a sustainable future. Its focused on achieving harmony between its manufacturing activities and the environment based on the concept of 'a plant that optimally utilizes natural resources while operating in harmony with the natural environment, thus working towards one of the national issues of energy security.

Toyota being a leader in the environmental stewardship started its journey towards greening its energy source since 2015-16 and has made substantial step-up over the years. TKM has gradually increased Green Energy Procurement and Investment in renewable energy sector to meet its energy requirements. The company has installed in-house solar power plants at roof tops and ground in its facility at Bidadi, which has a combined capacity of 8.4 MW of electricity. Toyota Kirloskar Motor has explored various possible avenues to increase its renewable energy share including inhouse solar parks, outside solar parks, open access sourcing etc. The renewable energy sourcing has increased from 15% in FY 15-16 to 65% in FY 17-18. The below reference tables showcase TKM’s energy source patterns over the years, towards optimization of renewable power usage at its plant facility:

Coal and other fossil fuels, which have taken three million years to form, are likely to deplete soon. Indian power sector being highly dependent on the coal based thermal power plants is one of the major sources of CO2 emission. For sustainable development, there is an urgent need to adopt energy efficiency measures with renewable energy sources such as wind, solar, etc. [replacing fossil fuels], being priority choices by wide varieties of manufacturing sectors. With these restructuring of energy supplies, we aim to reduce the emissions & its implications on the climate change. Also increasing renewable energy significantly allows to achieve cost effectiveness, providing economic advantage.

Speaking on Toyota’s commitment to environment protection and sustainability, Mr. Masakazu Yoshimura, Managing Director – Toyota Kirloskar Motor said, “Business can play a significant leadership role in accelerating the transition to a lower-carbon economy, we see renewable energy to be a key component of climate action efforts. As a responsible corporate citizen, we at Toyota strongly believe in the philosophy of “Respect for the Planet”. Reiterating our commitment to enable greener environment, TKM sources clean energy and adopts smart manufacturing systems towards Toyota’s ultimate global mission of ‘Zero Carbon Emission”.

Over the years, TKM has been stringently working towards reduction of dependency on non- renewable energy resources by implementing various energy management procedures to achieve environmental sustainability. Our renewable energy strategies prioritize energy efficiency and policy advocacy, well aligning with Government’s initiatives. I am very proud to declare that during October 2018, we achieved 100% renewable power source for our energy requirements. Through such significant goals, TKM could effectively contribute towards emission reduction by over 51,000 tons of Co2 during first three quarters of FY 2018-19.” He added.

In addition to these efforts, TKM has also devised strategies to reduce the Co2 emissions at its manufacturing facilities through energy “Consumption Reduction” and “Conversion Efficiency”. Under Conversion Efficiency enhancement approach, TKM aims to improve the operational efficiency by transforming energy from one form to another form through continuous

improvements which has been contributing effectively towards maximization of green energy adoption at TKM’s manufacturing plant.

Additionally, through various initiatives like adoption of reverse refrigeration system, centralized control of chillers, adoption of smart ACs, TKM has been reducing significant quantity of Co2 releases over the years. The company has also been vesting enormous efforts to reduce its energy consumptions through controlling and reducing daily energy consumption in each of the operational processes instilling stringent & systematic monitoring to track energy usages.

Recognising these efforts on reduction of emission in TKM’s manufacturing plant with key contributor being optimisation of renewable energy, TKM was recognised as a “Model Plant” under its “Zero Co2 plant” challenge among the Toyota Asia-Pacific affiliates.

Apart from the above stated key environmental conservations, TKM has been successful in adopting effective energy conservation techniques on factory floor and outside the company:

-   Aligning with the eco-commitment, TKM have been considerably focusing on environmental factors beginning with the plant design stage, the second plant facility at Bidadi was established, being “Eco-factory”. With this concept, TKM installed state-of- the-art technologies like servo press, global body welding line, wet on wet painting with enhanced energy efficiency levels of the manufacturing equipment, resulting in the overall reduction of Co2 emissions

-   With the concepts of Yosedome – flexibility to alter the scale as per production needs and ‘Kara- kuri' [an innovative process that converts electricity driven processes in to gravity and mechanically driven process], TKM has been driving continuous improvements to simplify and streamline the manufacturing processes, developing to become more energy efficient

Toyota is set to challenge the goal of ZERO CO₂ emissions by 2050. From fuel efficient vehicle to developing ever better eco techniques & approaches, TKM focuses on environmentally sustainable solutions in each of its business operations and every single vehicle that is manufactured in the plant facility.

The market dynamics are changing, the industry needs to acquire or develop alternate technologies to cater to future mobility needs. We at Toyota primarily focus on solving larger issues faced by the nation than just manufacturing world class cars. Such thinking way drives Toyota’s production system, products and services, national campaigns and all routine operations ensuring low emissions, fuel saving, energy conservation, safety as a prerequisite.

As pioneered makers of eco-cars leading the way for a better tomorrow, Toyota recently launched The All New Camry Hybrid Electric Vehicle. Toyota’s strong hybrid technology not only aims at creating harmony with man, nature and machine, but also positioned as the future of eco-mobility. The Camry Hybrid or self-charging electric vehicle is a strong hybrid and the only hybrid which is locally manufactured at Toyota Kirloskar Motor’s second plant located at Bidadi [Bangalore, Karnataka] in India. Toyota celebrates global cumulative hybrid sales of more than 12 million with the reduction of 94 million tons of Co2.