Working Toward the Mobility Society of the Future
Message from
the President
The Source of Our
Value Creation:
What Makes Us Toyota
Value Creation Story:
Working toward the Mobility
Business Foundations
for Value Creation
Corporate Data
Society of the Future
> Making Ever-better Cars > Initiatives to Achieve Carbon Neutrality
Software and Connected Initiatives > Commercial Sector Initiatives > Woven City
Initiatives to Achieve Carbon Neutrality: Monozukuri (manufacturing)
Taking on the Challenge of
Embodying Skilled Manufacturing, a
Key to the Future
Manufacturing has long been the main driving
force behind Japan's industrial development.
However, we cannot take it for granted that
Japan's strength in manufacturing will last forever.
This strength, which has been nurtured over many
decades, could be lost for good if we fail to hold
on to it. Japan is an earthquake-prone country,
and its manufacturing prowess has been refined
by adversity. In truth, Japan's manufacturers have
been made even stronger by overcoming one
natural disaster after another.
When the Great East Japan Earthquake struck
in 2011, our plants and equipment suffered grave
damage due to the unprecedented scale of the
disaster, and the restoration of their operations
took a long time. However, having gone through
this trial, we have become even better at minimiz-
ing disaster damage through the emergency
handling of equipment and immediate crisis
response in other areas.
When the COVID-19 pandemic forced auto-
makers to suspend production in 2020, we
voluntarily started to produce masks, face shields,
Supported the reconstruction
of damaged equipment
2020
COVID-19
pandemic
2021
Restoration of
a plant affected
by a fire
and foot-operated disinfectant application devic-
es. We also employed our TPS (Toyota Production
System) to assist in the production of such goods
as medical gowns. In sum, it was proven that our
response to emergencies has become prompter
and more proactive.
When a fire broke out at a semiconductor parts
manufacturing plant in 2021 and forced it to halt
production, we pulled together to support its
restoration efforts. With our teams in charge of
parts procurement and equipment manufacturing
demonstrating outstanding collaboration, the
damaged equipment was reconstructed in two
months. We thus accomplished a difficult task
that would otherwise require at least seven months.
Monozukuri (manufacturing) is about developing
people. It is not an exaggeration to say that
Japan, which turns hardships into strengths, is an
optimal place for manufacturing.
A Path toward a "Green Factory"
Toyota is currently taking on the challenge of
creating a "green factory" on various fronts to
realize a target of reducing the volume of CO2
emissions from its plants worldwide to zero, that
is, achieving carbon neutrality, by 2035.
Our commitment to the above target was
announced in June 2021.
A Path toward a Green Factory
Volume of CO2 emissions if
left on the present course
CO2
Reduction through
technological innovation &
daily continuous
improvement
We believe that striving for carbon neutrality
presents an opportunity to fundamentally
innovate manufacturing.
Technological Development Aimed at
Contributing to Carbon Neutrality
For example, we are engaged in technological
development that makes full use of new ideas.
Painting and casting are the most carbon-
intensive automobile manufacturing processes.
Based on new ideas, we are taking on technologi-
cal development focused on decarbonizing the
above two processes.
Conventional air-spray technologies are
designed to deposit paint over broad areas.
Moreover, with the air blown toward the target
surface rebounding off it and scattering paint
particles, only approximately 70% of the paint
being sprayed successfully adheres to the target
surface while the remaining 30% goes waste. To
eliminate such waste, our airless painting ma-
chines take advantage of the world's first technol-
ogy that uses static electricity to cause fine paint
particles to adhere to the target surface. This
technology enables us to achieve a coating
adhesion efficiency of more than 95%.
Furthermore, having combined this technology
Aiming for
early
achievement
Toyota Times
Is Manufacturing Past Its
Prime? Toyota Chief
Production Officer Says "No"
with the innovative concept of a rotating paint
ejection head, we have made it possible to create
even finer paint particles with minimal variation in
size, thereby achieving even higher painting
quality. In addition to curbing CO₂ emissions from
our manufacturing operations via the introduction
of airless painting machines, we are also able to
reduce the size of paint recovery equipment as
the volume of waste paint is considerably smaller.
Thus, airless painting machines will help us
achieve a significant reduction in the volume of
CO2 emissions.
Also, in an effort to upgrade the press molding
process for body panels, we are striving to make
use of in-mold coating technology in which paint
is applied to body panel parts as they are shaped
within the metal press molds. The integration of
press molding and painting into one process is an
epoch-making idea that could eliminate the
conventional painting process.
Other new ideas include replacing paint with
adhesive film, effectively eliminating the painting
process. Adhesive films can be customized to
make them special, and they can also be replaced
for fun. Drawing on this idea, we intend to take on
a new business in which we renovate used
vehicles, make them look fantastic, and offer them
to the users of the KINTO subscription service.
Assembly 3%
Press 3%
Volume of CO2
Emissions by Process
(2021: Toyota Motor
Co., Ltd. on a
non-consolidated
Thermal treatment 5%
Welding 5%
Molding 3%
Other 3%
Painting 26%
of carbon
neutrality at
plants
Painting
basis)
Forging 7%
2011
Great East
Japan
Earthquake
Supported restoration efforts
undertaken in disaster-hit
communities
Assisted in the production of
medical gowns
Volume of
CO2 emissions
Reduction through
renewable energy,
hydrogen use, etc.
(Including the use of CO2 credits)
2035
2050
Striving for carbon neutrality presents an opportunity to
fundamentally innovate manufacturing
Casting
TOYOTA MOTOR CORPORATION
24
INTEGRATED REPORT
Air-conditioner-
related 10%
Development of Technologies That Embody New Ideas
Case 1: Splatter-free painting
Machines 18%
Casting 17%
Case 2: Elimination of the painting process
(in-mold coating)
In-mold coating serves as a key to
integrating press molding and
painting processes
Materials used
Coating efficiency: Coating efficiency:
70%
95%
in the processView entire presentation