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 2018 we made 2,080 energy-saving improvements, upgraded to high-efficiency cogeneration (two units), and brought technology development projects on line (three projects). As a result, CO2 emissions per unit fell to 75, indexed to fiscal 2013, below our target of 76. Due to aggressive energy-saving activities, CO2 emissions of Group companies also fell below their target of 68, reaching 68 compared with the fiscal 2013 level.

Specific Initiatives

(1) Promoting Technological Development in Production Processes 

Of the greenhouse gases emitted as a result of DENSO’s production activities, 95% are accounted for by CO2 associated with energy consumption. DENSO is engaged in the Group-wide promotion of energy conservation activities as long-term CO2 reduction measures from three perspectives: making innovations in production processes, introducing thorough on-site improvements and high-efficiency facilities and equipment, and utilizing cogeneration and renewable energy.

The features of DENSO’s energy conservation activities are to identify latent issues by visualizing the energy consumption of individual production lines and by visualizing progress in activities, as well as for all employees to undertake improvement measures (Perfect Energy Factory [PEF]) and move production facilities in-house, promoting production facility energy conservation through the proprietary development of production technologies.

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.

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.

Emissions per unit worsened as a result of the plunge in production we experienced in fiscal 2010, 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.

DENSO Wins Two Energy Conservation Grand Prizes in the Successful Case Category

As part of its factory-improvement efforts, DENSO has successfully rolled out energy-conserving efforts across its factories. Accordingly, we have enthusiastically applied for the Energy Conservation Grand Prize, sponsored by The Energy Conservation Center, Japan (ECCJ); and in fiscal 2017, we received two such prizes.

  • Theme under which we received the Director-General’s Prize of the Agency for Natural Resources and Energy:“Procedure to test for helium leaks based on a new concept”
  • Theme under which we received the Chairman’s Prize of ECCJ:“Initiative to halve air use by making invisible air visible”

 

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) Employing Cogeneration and Renewable Energy

DENSO employs cogeneration utilizing LNG, a relatively low emitter of CO2, and waste heat. We have worked proactively since 1991 to make cogeneration a pillar of our energy conservation efforts. Since fiscal 2015, we have been working to reduce CO2 further through successive upgrades to high-efficiency cogeneration.

Denso Corporation (Japan) In-house Power Generation Rate via Co-generation (March 2018)

Introduced 15 units
In-house power generation rate 44% (total power generation: 6.84 million kWh)
CO2 reduction effect 200,000 tons of CO2 (annually)

Electric power usage (fiscal 1991-fiscal 2018)

Introducing Superior Low-Carbon Technologies at Group Companies Overseas (Emerging Markets)

Utilizing the Joint Crediting Mechanism (JCM), we are accelerating the update of superior low-carbon technologies at DENSO Group companies in emerging markets. To date, we have used this mechanism to introduce cogeneration in Thailand and Indonesia, helping to reduce CO2 emissions by approximately 14,000 tons per year.

Going forward, we will continue contributing to global warming countermeasures through the aggressive development of low-carbon technologies.

(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]

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