Minimum CO2 Monozukuri (Manufacturing)

Basic Stance

To address global warming due to climate change in the field of manufacturing, DENSO (1) promotes technological development in production processes; (2) ensures thorough employee participation in energy conservation, from departments that supply energy to those that use it; and (3) utilizes renewable energy. By working proactively to reduce CO2 in these ways, we aim to halve our energy use by fiscal 2026 (halving CO2 emissions per unit compared with fiscal 2013), while intensifying energy conservation activities with a view to achieving carbon neutrality by 2035.

Progress on Meeting CO2 Emissions Targets

Throughout the Company, in fiscal 2022 we made 2,200 energy-saving improvements. As a result, CO2 emissions per unit (non-consolidated basis) fell 48%, indexed to fiscal 2013, to 52. Due to aggressive energy-saving activities, CO2 emissions of Group companies declined 43%, to 57, compared with the fiscal 2013 level.

CO2 emissions per unit (Scope 1 and 2) (Global, DENSO Group)

Specific Initiatives

(1) Promoting Technological Development in Production Processes

Dantotsu (Outstanding) Factories

In terms of DANTOTSU factory activities, since 2012, DENSO has been engaged in technological developments to realize factories with stronger competitive capabilities through production sites promoting competitiveness and improvements, lean and highly productive automation, and synchronous integrated production with no inactivity. To achieve ENERGY 1/2, reduced energy consumption related to production is being promoted across the entire DENSO Group through the global deployment of technological developments including 1/N facilities development and automation.

  • Dantotsu (Outstanding) Factories

1/N Facilities Realizing DANTOTSU Factories (Case Study)

  • 1/N Facilities Realizing DANTOTSU Factories (Case Study)

(2) Ensuring Thorough Employee Participation in Energy Conservation, from Departments That Supply Energy to Those That Use It

Energy Just-in-Time (JIT) Activities

Based on the idea that “energy for production is not fixed infrastructure but another component to be controlled,” DENSO is working to establish a system for the utilization and supply of just the right amount of energy at the necessary time through energy JIT activities.

In fiscal 2010, emissions per unit worsened as a result of the plunge in production we experienced due to the global financial crisis. To address this situation, we have worked to create an energy-saving manufacturing structure that is resilient in the face of variations in production. We now include energy conservation as a basic tenet of our facility design and production activities.

In 2020 and 2021, emissions per unit temporarily worsened due to the decline in production brought about by the COVID-19 pandemic. However, by the end of the fiscal year, emissions per unit improved 13% as a result of strengthening such measures as comprehensive JIT inspections of energy supply divisions and the consolidation and idle stoppage of production lines as well as implementing thorough, organization-wide energy-saving activities that covered everything from energy supply to use.

  • Energy Just-in-Time (JIT) Activities

    * FEMS: Factory Energy Management System, an energy management system that supports the efficient use of energy in buildings

DENSO Wins Prizes at the Energy Conservation Grand Prize Awards in Fiscal 2022 for the 12th Consecutive Year

As part of its factory improvement efforts, DENSO has successfully rolled out energy-conserving efforts across its factories. Accordingly, we enthusiastically apply for the Energy Conservation Grand Prize Awards, sponsored by the Energy Conservation Center, Japan, with cases of improvements implemented at our factories that are highly effective in saving energy and have the potential for horizontal deployment. Since fiscal 2010, we have won prizes at the Energy Conservation Grand Prize Awards for 12 consecutive years.

    • 2021

    Winning the Prize of the Chairman of The Energy Conservation Center

    “Taking on the challenge of reducing the volume of pure water used for steam heating by 50% through the effective use of water-cooled heat pumps”
    (Semiconductor Manufacturing Division 2)

Support for Energy JIT at Group Companies in Japan and Overseas

We support introduction activities to encourage the proliferation of Energy JIT throughout the DENSO Group.
Specifically, in fiscal 2021, we renewed the Perfect Energy Factory (PEF), a collection of case studies of generic and highly economical energy-saving improvements on the supply and production sides, including Energy JIT activities, and are promoting activities to re-examine them at Group companies in Japan and overseas. We have visited 21 Group companies in Japan since fiscal 2022, contributing to a reduction of approximately 3,000 tons of CO2 per year.

(3) Realizing Carbon Neutral Plants

Amid the recent acceleration of the global shift toward decarbonization, DENSO has begun to implement initiatives aimed at realizing carbon neutrality in its manufacturing. Efforts include strengthening energy-saving activities through the use of Factory-IoT and the introduction of digitalization, as well as switching to electricity derived from renewable energy and establishing technologies to capture, recycle, store, and reuse CO2.

For example, we have developed a CO2 circulation plant,* a facility designed to capture and circulate CO2, using technologies we have refined through development in the automotive domain, and have begun verification tests at the Anjo Plant, in Aichi Prefecture. We will introduce CO2 recycling plants at the Anjo Plant, Hirose Plant, Nishio Plant, and DENSO FUKUSHIMA CORPORATION—our four designated model plants in Japan—and gradually expand the number of CO2 circulation plants to 130 worldwide. We will work on further technological developments for the CO2 recycling plants geared toward their social implementation, thus contributing to realizing carbon neutrality throughout the entire Company.

In fiscal 2022, we achieved 100% renewable energy at the Anjo Plant (electric and gas), six bases in Europe (electric), and one base in Asia (electric), through measures such as the installation of solar power generation facilities and the use of carbon offset certificates.

Note: Technology developed in collaboration with Toyota Central R&D Labs, Inc.

    • CO2plant

    The CO2 Circulation Plant was built adjacent to the Anjo Plant in Aichi Prefecture. 

    • CO2plant

    Equipment within the CO2 Circulation Plant

DENSO CO2 circulation plant

If We Don't Do It, Who Else Is Going To?

  • At the moment, the CO2 Circulation Plant is still a prototype. By actually undertaking this development project ourselves, we were able to see where to make improvements in order to realize the introduction of CO2 circulation plants. To achieve the population of these plants, we first need to make improvements on a consistent basis in order to prove with confidence that the practical application of these plants is in fact feasible. Going beyond that, we need to show that these plants can work in any environment by introducing them in DENSO plants around the world. If we can accomplish these tasks, I am sure that these plants will be adopted around the world. Also, establishing frameworks for CO2 circulation are not something we can fully achieve on our own. For that reason, we hope to team up with a wide range of partners. With the hope that young people, who will lead the next generation, can live in a healthy, more pleasant world, we will continue to move forward with this project with a strong sense of responsibility.

    • Environment Neutral Systems Development Division

      Environment Neutral Systems Development Division
      From left: Masayuki Suzuki, Youhel Morimoto, and Shinya Sakaguchi

(4) Reducing CO2 Emissions within Logistics Activities

DENSO strives to reduce CO2 from logistics through distribution improvements.

In Japan, we consign distribution operations to DENSO Logitem Corporation, a subsidiary, and work together to promote CO2 emissions reduction at specified shippers in efforts to fulfill our social responsibility. Specifically, we are cooperating with a focus on a composite program that includes the following measures:

  1. Improving loading ratios

  2. Using optimized routes to save energy during transport

  3. Shortening transport routes to suppliers through production area transfers

  4. Increasing efficiency of logistics between factories/intermediary warehouses

  5. Promoting modal shift (to rail or ship transport)

  6. Introducing tools to enhance fuel efficiency

CO2 emissions from logistics [DENSO CORPORATION]
Fiscal year 2013
(base year)
・・・ 2018 2019 2020 2021 2022
Thousand t-CO2 34.4   34.3 41.8 43.2 40.4 45.5

Amount of CO2 emissions in logistics / Physical production and sales (Unit: 100 million yen) [DENSO CORPORATION]

We have achieved reductions in logistics CO2 emissions through logistics improvements, such as increasing loading ratios, shifting to rail and sea transportation, and reducing transportation distances to delivery destinations.

  • Amount of CO2 emissions in logistics / Physical production and sales (Unit: 100 million yen) [DENSO CORPORATION]

    *Asmo Corporation was integrated into Denso Corporation (April 2018).