Mazda promotes the efficient use of energy while aiming to reduce CO2 emissions in the area of manufacturing.
The total CO2 emissions from Mazda's four principal domestic sites*1 (including R&D and other indirect areas) in FY March 2014 was reduced by 43.3% compared with FY March 1991 levels due to the following measures.
- Further implementation of Monotsukuri Innovation
- Improvements in overall facility operating efficiency
- Concentrating production and reducing losses from unnecessary work and equipment downtime
- Total CO2 emissions from Mazda's four principal domestic plants reduced by 43.3% (533,000 tons - CO2)
- Emissions per unit of sales revenue reduced by 38.7% (25.9 t-CO2/100 million yen)
- *1Head Office (Hiroshima); Miyoshi Plant; Hofu Plant, Nishinoura District; Hofu Plant, Nakanoseki District.
|Fuel oil A||596||46||69||32||20||20|
|Fuel oil B||11||0||0||0||0||0|
|Fuel oil C||1,168||91||81||60||36||30|
In line with its efforts to satisfy diverse customer needs and attract many customers by manufacturing vehicles that embody the "Sustainable Zoom-Zoom", Mazda is working to dramatically improve its business efficiency by increasing product development/manufacturing efficiency. To improve quality and the brand strength, as well as to increase profit margins, while flexibly responding to requirement for manufacturing of several models with different production scales and changes in production volume, a breakthrough of "sharing a completely new concept beyond boundaries of models" is necessary. This idea has resulted in generation of the "Monotsukuri innovation".
Product development, manufacturing, and purchasing divisions/departments mutually cooperate in planning the models to be introduced in the future across the vehicle ranks and segments from a five or ten-year perspective, which enables efficient product development and manufacturing of diverse types of products with common product development methods or production processes. Under this initiative, at the timing of introducing new models equipped with the SKYACTIV Technology, Mazda has substantially reduced per-unit energy consumption. Specific efforts are as follows:
- Material: Reduced material weight through using thinner parts, shortening cycle time, integrating processes, and modifying production methods, so as to reduce energy consumption.
- Processing and assembly: Evolved conventional flexible manufacturing lines to realize higher-efficiency, mixed flow production, which resulted in dramatically improved operating rates and reduced energy consumption.
- Press: Reduced the amount of scraps generated in manufacturing of press parts, and retrieved parts from scraps to reduce the amount of use of steel sheets. Also achieved multi-pressing, which performs molding of several parts using a single die, resulting in both integration of processes and reduction of energy consumption.
- Paint: Developed and introduced the Aqua-Tech Paint System, a new water based painting technology that enables elimination of the primer process while further improving the painting performance and quality, resulting in reduced energy use for air conditioners in painting booths, and substantial reduction of VOC (volatile organic compound) emissions. This Aqua-Tech Paint System won the Director General Prize of Agency of Natural Resources and Energy (Exemplary Energy Conservation Category) in FY March 2014.
Body Production Engineering Department,
Production Engineering Division
We are in charge of process and mold design in the manufacturing of press-molded parts. Regarding the process and mold design for the new Demio (Mazda2 overseas), we made efforts in improving the yields of parts with less steel plating, contributing to resource savings. In collaboration with relevant divisions and departments, we will continue taking on the challenge to pursue press forming of complex-shaped parts for superior design quality, one of Mazda's strengths, while maintaining and enhancing our products' high quality.
At production sites in Japan and abroad, improving the facility operation rate, shortening cycle time, and other measures are being taken to optimize the line process as well as the entire manufacturing process. Also, losses in each step from production to consumption of energy are reanalyzed to further cut losses, including cutting losses by suspending the power supply (for hydraulic pressure, etc.) during standby.