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) employs cogeneration and 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).

Progress on Meeting CO2 Emissions Targets

Throughout the Company, in fiscal 2021 we made 1,960 energy-saving improvements, upgraded to high-efficiency cogeneration (three units), and brought technology development projects on line (four projects). As a result, CO2 emissions per unit (non-consolidated basis) fell 40%, indexed to fiscal 2013, to 60. Due to aggressive energy-saving activities, CO2 emissions of Group companies also declined 40%, to 60, compared with the fiscal 2013 level.

  • Progress on Meeting CO2 Emissions Targets

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 fiscal 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 6% 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

Topics:DENSO Wins Two Prizes at the Energy Conservation Grand Prize Awards in the Successful Case Category in Fiscal 2021

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 (ECCJ). Since fiscal 2010, we have won prizes at the Energy Conservation Grand Prize Awards for 11 consecutive years and 12 years in total, including winning the Director-General Prize of the Agency for Natural Resources and Energy for the fourth year in a row.

    • energy02-img-energy-awards-2020-01

    Winning the Director-General Prize of the Agency for Natural Resources and Energy

    “Promotion of energy-saving activities by optimizing the manufacturing process of high-precision resin molded components”
    (Mechatronics Components Manufacturing Division)

    • energy02-img-energy-awards-2020-02

    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, we form teams comprising energy conservation specialists and on the supply and production sides for improvement projects that take a comprehensive look at Group companies, from power plants to production facilities, working on site with local staff members to identify issues. Since beginning these support activities in 2014, the teams have visited 15 companies in Japan and overseas, contributing to a reduction of approximately 20,000 tons of CO2 per year.

(3) Use of renewable energy

As part of our efforts to reduce CO2 emissions through the use of renewable energy, in fiscal 2021 we established a 1,500-kw solar power generation facility and a 560-kw solar power generation facility at the Zenmyo Plant and Anjo Plant, respectively, thereby helping to achieve an emissions reduction of 330t-CO2.

    • energy02-img-zenmyo-plant

      1,500-kw solar power generation facility at the Zenmyo Plant (March 2021 activity)

(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)
・・・ 2017 2018 2019 2020 2021
Thousand t-CO2 34.4   33.6 34.3 41.8 43.2 40.4

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

  • 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).