Mazda builds resource-saving initiatives into every phase of the life cycle of its vehicles, based on the three Rs: reduce, reuse, and recycle. The Company implements thorough recycling and waste-reduction initiatives in the areas of manufacturing and logistics as well, in order to ensure that limited resources are used effectively.
【Manufacturing】Maintaining the Status of Zero Landfill Waste and Promoting the Reduction of Waste
To reduce landfill waste at its four principal domestic facilities*1 to zero, Mazda is promoting reductions in the volume of manufacturing byproducts and waste, more rigorous sorting of waste, and recycling. As a result, the Company has achieved zero landfill waste, and has maintained this status from FY March 2009 to FY March 2016. In addition, by promoting Monotsukuri Innovation, replacing steel with aluminum as a parts material, and implementing even more rigorous sorting of waste through the introduction of magnetic separators, the Company has reduced the amount of waste*2 by 81% compared with FY March 1991 levels.
Changes in the Amount of Landfill Waste
FY March 2016 Recycling of Manufacturing Byproducts and Waste in the Manufacturing Areas
*1 Head office (Hiroshima); Miyoshi Plant; Hofu Plant, Nishinoura District; Hofu Plant, Nakanoseki District (including nonmanufacturing areas such as product development)
*2 The figures of the amount of waste at four principal domestic sites in FY March 2016 have been verified by a third party.
<Efforts at Overseas Plants >
AutoAlliance (Thailand) (AAT) established a Recycle Bank Project (a project to collect recyclable waste) to promote classified waste dumping. This led to a 19% reduction in incinerated waste to 6.0 kg/unit in FY March 2016 (FY March 2015: 7.5 kg).
Mazda Powertrain Manufacturing (Thailand) (MPMT) is thoroughly enforcing the sorting of waste to promote the reduction of the volume of waste and recycling.
【Logistics】Reducing Volume of Packaging and Wrapping Materials
Mazda is moving forward with efforts centering on the "three Rs of Mazda logistics" to cut down on resources used for packaging and wrapping. The target for packaging and wrapping materials was a reduction in volume of 47% or more from FY March 1991 levels; in FY March 2016, a 54%*3 reduction was achieved.
Since FY March 2013, furthermore, Mazda has been continuing activities to reflect logistics needs at the beginning of product development, so as to include improvement of packaging and wrapping specifications in the product design and development processes. These activities, targeting parts to be shipped to overseas KD*4 production sites, aim to achieve an ideal form of transportation by considering efficient logistics in the development stage of work processes, from design to production and shipment, and optimizing parts specifications and structures. In FY March 2014, the volume of packaging and wrapping materials for some new models was reduced by optimizing component shapes and packaging. In FY March 2015, the Company applied this approach to an even wider variety of models. And for some parts, the Company enabled the containers that are used to hold double the previous volume of parts.
To help realize the global procurement of parts, the Company has established a distribution center in Thailand, thereby promoting even more effective transportation. At the same time, for transportation to Japan, as well as parts transportation covering (some) suppliers in Thailand, the Company has considerably reduced waste volumes, by reusing packaging and wrapping materials and containers from Japan to Thailand and vice versa.
In FY March 2016, the Company succeeded in reducing waste generated from repackaging by enabling the supply of parts provided by suppliers in Thailand to the production line in the packaging that they came in.
The Company will continue promoting and expanding these activities that involve efforts in the product design and development processes.
*3 Forecasted reduction rate compared with measures similar to those performed in FY March 1991
*4 A manufacturing method wherein parts are exported to overseas production sites, where they are assembled onsite.