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Establishment of Recycling Society
Preservation of the world’s resource bases is a major theme of ISO26000, GRI Standards 2016, and Sustainable Development Goals (SDGs). And, there is a strong demand on companies to reduce their usage of raw materials and to utilize recycled parts. In addition, due to the concern of global water shortages in the future, it is becoming increasingly important for companies to engage in activities for the effective utilization of water resources. At JTEKT, we make improvements and devise the method for the production processes of each product, aiming to reduce material usage and waste output, and to promote recycling. This initiative finally, results in saving valuable resources through monozukuri.
Main results of activities in FY2018
Waste output in production (independent)6.20 t/100 million yen (25.8% decrease)
Waste output in production (global)9.60 t/100 million yen (7.1% decrease)
Water usage by in-house production  (independent)1,350 m3/100 million yen (26.0% decrease)
Water usage by in-house production   (global)1,050 ㎥/100 million yen (53.1% decrease)

Activities report
Waste reduction <Production>

Initiatives for waste with high discharge volumes
JTEKT engages in efforts to categorize waste materials (recycling items for free or at a charge) and prioritizing improvements for waste for which there are high discharge volumes with a focus on the major items of casting sand, sludge, and waste oil.
FY2018 waste ratios (JTEKT non-consolidated)
Initiatives for achieving Zero Emissions
JTEKT has been engaging in activities based on 3R (Reduce, Reuse, Recycle) to achieve the 100 percent recycling rate for the effective use of resources regarding all discharged materials, including waste. The result was the achievement of the 100% recycling rate in November 2012, which we have maintained ever since. We continue promoting recycling in order to achieve Zero Emissions in our operations on a global scale by the year 2020.
• What is “Zero Emissions”?
The practice of utilizing waste and byproduct created through industrial activities as resources for other industries in an attempt to avoid releasing waste into the natural world on the whole. This concept was proposed by the United Nations University in 1994.
Processing of industrial waste and recycled materials
*Amount handled externally (incineration waste):Zero
*Direct landfill waste: Zero
Transition in discharge amount
JTEKT non-consolidated
Global
Transition in waste base unit
* JTEKT calculates the discharge of the waste categorized as “Special Control Industrial Waste” in Japan,
and the waste stipulated as “hazardous waste” for each overseas country where it has operations.
*Within Japan: Left-hand scale (unit: t), Overseas: Right-hand scale (unit: 1,000 t)
Main measures

Coolant tank shape change for increased sludge collection <Domestic plant: Tadomisaki Plant>

The JTEKT Tadomisaki Plant is working to extend the product life of coolants by installing cyclone filters in the tanks to remove sludge from the coolant. Up to now, insufficient removal of sludge that had accumulated in the corners of the tanks had reduced the life cycles of the coolants. Installing walls at the corners of the tanks creates a smooth, spiral flow, preventing the accumulation of sludge at the corners. As a result, replacement of coolants four times a year was cut down to twice a year, reducing the amount of coolant waste by half as well as the workload for coolant replacement.

Waste
reduction by 4 t/year

Effective utilization of resources  <Reduce waste in production>

Effective utilization of resources  <Reduce waste in production>
JTEKT is working to reduce material consumption through the application of the net shape method (contributing to reduction of machined portions) as well as working on weight reduction by using composite materials by improving the technologies related to casting and forging.
Main measures

Forming the bearing inner and outer rings together and reducing machining allowance with a CR finish

Changing the process of forming the outer and inner rings of bearing parts to a single operation has reduced the amount of scraps produced when punching the hole. JTEKT is also working to develop a method to reduce machining chips by shifting the process from turning to rolling when forming grooves.
Reduced weight
Approximately 77 t/year
Initiatives for reduction of secondary material consumption
JTEKT is promoting the reduction in the consumption of the secondary materials such as dies, grinding wheels and cutting tools, by revising the quality of material, shape, hardness and other specifications so that they could have further durability. Also we endeavor to promote reusing and recycling of used oil, grinding wheels, cutting tools and jigs.

Retouching and reusing header cemented carbide die

JTEKT is working to prolong the product life of cemented carbide dies that had previously been disposed of due to cracks and frictional wear by polishing and retouching the cracked and worn parts.
Die product life
Approximately doubled

Waste reduction
<Logistics>

Reduction of packaging material
In FY2018, JTEKT promoted the use of returnable, reusable, and simplified wood and paper packaging with a focus on replacing wooden pallets with plastic pallets. We successfully reduced the use of wooden products; however, the amount of paper product purchases increased due to an increase in products that required single boxes and cardboard boxes. In FY2019, JTEKT will promote the reduction of paper packaging materials through activities which include replacing disposable cardboard boxes with returnable plastic cases, reviewing excessive packaging, and changing the size of cardboard boxes to match the size of the product and reduce the amount of cushioning material used.
Transition of wood packaging usage/per base unit
Transition of paper packaging usage/per base unit

Promoting usage of returnable packaging in exported goods

1) In FY2018, JTEKT achieved packaging material reduction by switching from using wooden pallets to returnable plastic pallets.
2) In FY2019, JTEKT will promote initiatives focusing on the use of appropriately sized cardboard boxes and the proliferation of plastic cases.

Effective utilization of resources
<Reduction of water consumption>

Promoting the effective utilization of water

To reduce the usage of water, a precious resource, we engage in internal activities to decrease wasteful usage and recycle water. In FY2018, we had at first planned to improve our base unit and consumption amount by 6% or more compared to FY2012, however we achieved this goal ahead of schedule in FY2016, therefore setting the new target to improve the figure compared to FY2017 by 0.5% or more. As a result, we achieved improvement by 5.6% (80 m3/100 million yen) in base unit and reduced consumption by 1.9% (45 m3/100 million yen). With the aim of achieving an improvement of 0.5% or more compared to FY2018 in FY2019, we are promoting the recycling of cooling water in the heat treatment process at our Tokushima Plant.
Water consumption/base unit transition/amount of recycled water
Water usage
Water usage per base unit
Amount of recycled water

Water risk assessment

In addition to effectively using water resources by improving the water consumption base unit, JTEKT has been assessing water risks at each business site using Aqueduct* since 2017.
JTEKT will continue to work to reduce water consumption and effectively use water resources through activities based on water risk assessment results including future predictions and water consumption and water dependency at each business site.
※Aqueduct
A database operated by the World Resources Institute (WRI) that provides world maps and information showing water risks such as physical water stress, water quality, regulatory risk concerning water resources, and reputational risk.
*Data collection targets: Global environmental management target companies (13 JTEKT independent bases, 19 domestic group companies, 38 overseas group companies)

Water risk countermeasures

As a result of water risk assessment, the Indian region and the Dalian China region are rated as having high water risks in all of JTEKT Group’s production bases.
Additionally, as a result of investigating actual water usage and water conditions in water risk areas, water quality is poor in the Indian region, so an RO (reverse osmosis) membrane device has been installed to supply improved quality water to the production process.
Water consumption is relatively low in water risk areas (India: 172,000 m3, China: 187,000 m3), so the risks associated with water use are considered to be limited.
Therefore, we are currently working on reducing water usage at the Tokushima Plant and JALY (France), which consume large amounts of water sourced from groundwater and river water.
Main measures
Domestic plant: Tokushima Plant

Efforts to reduce water usage in the heat treatment processes

The Tokushima Plant has been promoting the reuse of heat treatment cooling water since FY2018 as a means of reducing groundwater intake. Until now, the cooling water of heat treatment equipment had been discharged into the river after use because the cooling water circuit has a sealed structure. Now, we are promoting the reduction of groundwater usage by introducing a circulation system in the heat treatment equipment at five plants with particularly large consumption (28,000㎥/month). In FY2018, measures were completed for two heat treatment equipment and five converter furnaces, reducing the amount of groundwater use by 14,690㎥/month (176,280㎥/year). The plan for FY2019 is to take measures against the remaining heat treatment furnaces by completing installation of the circulation system in the heat treatment facilities at all five plants.

MY CSR
Yusaku Yamamoto Facilities & Equipment Maintenance Section, Manufacturing Engineering Dept., Tokushima Plant, Bearings Business Unit
Striving for a sustainable society
The Tokushima Plant relies on groundwater for 97% of the water that it uses. With the recent surfacing of “water risks”, the reduction of water consumption and effective use of water resources are becoming worldwide issues. I will continue working to contribute to the sustainability of local water resources through activities including reduction of the amount of groundwater used.