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DENSO's Green Ways: Not just talking trash

 

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DENSO’s Green Ways
Not just talking trash

DENSO's new environmental policy covers
trash, water use, emissions and more

It was a mistake.

It was a mistake that led DENSO to focus on environmental consideration long before many other companies.

Here’s what happened. Some time after DENSO established its first factory in the midst of the rice farms in rural Kariya, Japan, we accidentally released wastewater that contaminated the rice farms around us, causing a poor rice crop for local farmers. While DENSO immediately responded by totally changing the factory’s wastewater drainage system, the event was a forceful reminder that we cannot exist without considering the environment and the communities around us.

That happened nearly 50 years ago, but we will never forget it.

One of DENSO’s key management principles remains: Environmental reservation and harmony with society. That’s not an easy principle to maintain with an estimated 800 million automobiles in operation around the world.

“Automobiles are an essential part of our daily lives,” said Mitsuo “Matt” Matsushita, DENSO International America (DIAM) president and CEO. “But they do have a negative impact on the environment. So it’s our responsibility to do everything we can to reduce that environmental burden and realize an advanced automotive society where autos and people can co-exist in harmony.”

And that’s why the North American environmental team has created a five-year environmental action plan for North America. The plan is based on DENSO’s global EcoVision 2015, our most recent 10-year environmental strategy for worldwide DENSO group companies.

DENSO’s environmental action plan kicked off in April at all DENSO group companies in North America, and DIAM announced the plan in March to journalists at a special media event.

The action plan is divided into four categories:

Eco Products: DENSO will develop products that are lightweight and energy saving and consider environmental improvement. We will reduce our use of resources; control and reduce environmentally hazardous substances such as hexavalent chromium, cadmium, mercury and lead, and make environmental planning part of the product design process.

Eco Factory: We will work to reduce the environmental impact of our manufacturing facilities through reduced water reduced CO2 emissions; reducing landfill waste, and reducing emissions of hazardous substances.

Eco Management: DENSO will develop environmental action plans and reinforce environmental partnerships with suppliers through activities such as developing green procurement guidelines and promoting the purchase of
environmentally friendly products.

Eco Friendly: We will encourage and support environmental activities; proactive information disclosure and communication with stakeholders; environmental education, and environmental and social contributions.

“This isn’t just a fad, and this isn’t just a new horizon,” said Matsushita. “When we say we’re going to use less energy and resources, reduce emissions of hazardous substances and reduce landfill waste, we mean it, as we have done historically.”

 

 


DENSO’s commitment to the environment was the topic of our news conference at the North American International Auto Show in Detroit, Mich., earlier this year. More than 60 journalists attended the news conference and interviewed
DENSO executives, including Mitsuo “Matt” Matsushita, DENSO International America president and CEO.


By the numbers
In manufacturing facilities DENSO will reduce:

• Water use to 50 percent of our 1999 levels.

• Landfill waste by 75 percent of 1999 levels

• Hazardous substance emissions by 30 percent of 2000 levels

• CO2 emissions by 18 percent (by 6 percent in non-manufacturing facilities)


By 2010, DENSO will eliminate four hazardous substances from DENSO products and processes: mercury, cadmium, hexavalent chromium and lead.



Gary Vasilash, editor of Automotive Design and Production magazine, quizzes Gary Hughes (center) and Cory Tallent (right), both of DENSO Manufacturing Tennessee, about their gold-medal winning Quality Circle team, House of Payne. House of Payne helped DMTN save money and the environment by developing a system that reduces and reuses the ink waste created during the instrument cluster printing process. DENSO manufacturing facilities in Takatana, Japan; Laguna, Philippines, and Guadalupe, Mexico are incorporating this improvement into their plants.
Mike and Eric Ely, DENSO Manufacturing Michigan, demonstrate for a crowd of journalists how their third-prize winning Muran Contest invention, Samantha the Garden Robot Worm, works. The Elys were part of the DENSO team showing the media the many unique ways ENSO is focusing on environmental preservation. “Samantha” is powered only by water, and it aerates the ground and irrigates the soil as it inches along.
Show and tell
When we were ready to announce our North American Environmental Action Plan, we didn’t whisper the news—we invited journalists from business and automotive media to hear about our plan first-hand.

Journalists from publications including Ward’s AutoWorld, Automotive News and Bloomberg News attended the March 14
announcement at DENSO International America in Southfield, Mich., where Robert Townsend, senior manager, Environmental Safety and Health, gave an overview of our five-year plan.

But we didn’t just tell the journalists our plans. We showed them some of the things we’re already doing.

Cory Tallent and Gary Hughes from the Printing Department at DENSO Manufacturing Tennessee’s (DMTN) Instrument Cluster Plant, explained how their gold-medal winning Quality Circle (QC) team not only saved DMTN money, it also helped preserve the environment. The QC team, “House of Payne,” developed a system that allows them to save and reuse the ink waste generated during the screen-printing of instrument cluster dials.

The results? DMTN reduced its hazardous waste ink by more than 40 percent; going from 21 drums of waste ink in 2004 to five drums in 2005. The new procedure also reduced annual production costs by $156,000. And their idea is going global: DENSO Takatana in Japan; Philippine Auto Components in Laguna, Philippines, and DENSO Manufacturing Mexico now use this same process to reduce, reuse and recycle ink waste.

Mike and Eric Ely, from DENSO Manufacturing Michigan (DMMI) demonstrated their brainchild, “Samantha the Garden Robot Worm,” a water-powered robot that looks like an inchworm, which aerates and irrigates the soil as it moves. The worm, named Samantha after Mike Ely’s daughter, is unique because it has sophisticated controls that create a specific motion, allowing the robot to simulate the movements of a garden worm.


The Ely brothers entered their robot worm in DENSO’s bi-annual worldwide Muran or idea Contest, and were one of 142 innovations and creations from around the world selected to travel to Japan and present their invention to a panel of judges. Their worm took the third place prize.