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エフテックグループ環境報告書2013
Contents Editorial Policy ………………………………… 01
F.tech Group of Companies …………… 02
Message from President ……………………… 03
Company principle/ Action guidelines/ Environmental
principles & policies ……… 04
TOPICS 1 ………………………… 05-06
TOPICS 2 ………………………… 07-08
Environmental goals & results………………… 09
Environmental Mid Term Plan………………………… 10
Material flow ……………………… 11
Environmental Management ……………………… 12
Editorial Policy We have been issuing Environmental Report since 2010 as
environmental education as well as to inform our employees
about our environmental activities. For this issue we have focused
on not only our employees, but stakeholders to provide the
information in an understandable way. Also from the Corporate
Social Responsibility point of view we have expanded information
to corporate governance, compliance, environmental aspects and
social aspects as well. Activities of Quality Assurance, Health &
Safety and Community Activity are also disclosed in this report.
Guideline was referred by “2012 Environmental Report Guideline”
issued by Ministry of Environment.
F.tech Group described as F.tech or our group. F.tech Inc. is
mentioned as the company.
Reporting term
Results of FY2012 (04/2012 – 03/2013) and activities in previous terms
All F.tech Environmental load reduction activity
…… 13
Chemical Substance Contained in Products…… 14
Quality Assurance …………………… 15
Health and Safety ……………… 16
Global Activities ………… 17-20
Corporate Governance/ Compliance/
Risk Management ……… 21
Company profile …………………………… 22
将来の予測・計画・目標について
本報告書にはエフテックグループ＇株式会社 エフテッ
クとその 連結子会社14社（の将来に
Organization
－Japan－
F.tech Inc. [3 facilities]
★ Head office, Kuki Plant [Shobucho, Kuki, Saitama]
★ Haga Technical Centre [Hagacho, Tochigi]
★ Kameyama Plant［Kameyamashi, Mie］ Domestic company/ Affiliated company [4 facilities]
○ Fukuda Engineering Co., Ltd. (FEG) [Kazoshi, Saitama］
○ Kyushu F.tech Inc. (QFT) [Yamagashi, Kumamoto]
○ Reterra Co., Ltd. (Reterra) [Chichibu, Saitama]
○ Johnan Manufacturing [Uedashi, Nagano]
Subsidiaries in overseas [9 companies, 11 facilities]
－North America－
● F & P Mfg., Inc.(F&P) [Ontario, Canada]
● DYNA-MIG, A division of F&P Mfg., Inc. ＇DYNA-MIG（ [Ontario, Canada]
● F & P America Mfg., Inc. (F&PA) [Ohio, USA]
● F.tech R & D North America Inc. ＇R&DNA（ [Ohio, USA]
● F & P Georgia, A division of F&P America Mfg., Inc. (F&PG)[Georgia, USA]
● F.E.G. DE QUERETARO S.A. DE C.V. ＇FEGQ（ [Mexico]
－China－
● F.tech Zhongshan Inc. (FTZ) [Guangdong, china]
● F.tech Wuhan Inc. (FTW) [Hubei, China]
－Asia and Oceania－
● F.tech Philippines Mfg., Inc. (FPMI) [Laguna, Philippines]
● F.tech R & D Philippines Inc. (FR&DP) ［Laguna, Philippines］
● F.tech Mfg. (Thailand) Ltd. (FMTL) ［Ayutthaya, Thailand］
F.E.G. DE QUERETARO S.A. DE C.V. was added from this report.
関する予測についても記載しています。
これらの記載は、記載した現時点での情報に 基
づいた予測であり、確定的なものではありませ ん。
そのため将来の事業活動の結果が、本報告 書に
記載した予測とは異なる場合があります。
★ Facilities in Japan ○Affiliated company in Japan ●Affiliated company overseas
※ FUTIAN MOULD TECHNOLOGY (YANTAI) CO., LTD is not mass production factories and
therefore, they do not make impact on the environment. F&P MFG. DE. MEXICO S.A.DE C.V.
is just established the company and therefore, it is excluded in the report. F.E.G. DE
QUERETARO S.A. DE C.V. is in preparation.
F.tech Group of Companies
Accounts for77% of sales consisted by North America and Asia
We are expanding our network globally. ◎ Japan ● Consolidated subsidiaries ◇ Affiliated company
【Subsidiaries in overseas】
Japan/overseas sales
Japan
23％
Overs
eas
77％
◇ JOHNAN UK LTD.
【Companies in Japan】
◇PROGRESSIVE TOOLS &
COMPONENTS(P) Ltd.
●F.tech Zhongshan Inc. (FTZ)
● F.tech Wuhan Inc. ● F.tech Philippines Mfg., Inc.
● F.tech R ＆ D Philippines Inc.
● F & P Mfg., Inc.
● DYNA-MIG, A division of F&P Mfg., Inc.
● F&P America Mfg., Inc.
● F.tech R & D North America Inc.
● F&P Georgia, A division of F&P America Mfg., Inc.
● F.E.G. DE QUERETARO S.A. DE C.V.
● F&P MFG.DE.MEXICO S.A.DE C.V.
◎Head office, Kuki Plant
◎Haga Technical Center
●Fukuda Engineering Co., Ltd
● Reterra Co., Ltd.
◇Johnan Manufacturing
● F.tech Mfg. (Thailand) Ltd.
●Futian Mould Technology (YANTAI) Co., Ltd.
● F.tech R&D (Guangzhong) Inc.
◇ JHONAN F.TECH (THAILAND) LTD.
◇ JOHNAN AMERICA, INC.
◇ JOHNAN DE MEXICO, S. A. DE C. V.
◇Johnan Kuyshu Manufacturing ◎Kameyama Plant
◇ PT.JFD INDONESIA
◇ Johnan Wuhan
● PT.F.TECH INDONESIA
●Kyushu Ftech
Improvement and support of vehicle’s performance
by developing and manufacturing critical safety suspension parts
Speed, low cost, reliability, as well as responding to social needs such as safety and environmental performance means consistently working on planning, development and production.
We manufacture critical safety automotive parts such as suspension, subframe and pedal with our unique integrated manufacturing system (from planning to development, fabrication of die/equipment, hydroforming process, welding, ED paint and assembly)
Brake pedal
Steel front Subframe Steel and aluminum front
Subframe (welded two dissimilar
metals by FSW*)
Aluminum front Subframe
(Continuous weld by FSW*)
Rear Subframe produced by
hybrid aluminum process
Rear axle beam Lower arm Organ type accelerator pedal
* FSW: Friction Stir Welding
2
Advance the preparation of acquisition of ISO 50001 certificate, and be a “Top Runner” in the environmental race.
The 2
nd term of our Environmental Mid Plan, the last term in
FY2013, has been completed. As for prevention of global
warming activity, we established the system in 2008 that helped
to understand how much greenhouse gases we emitted in the
Ftech group, and since 2011we expanded its activity further to
our supply chain. The rate of data collected exceeded our goal of
90%. We will aim for 100% data collection in FY2013 and will
contribute to reduce the environmental load for the lifecycle of
our products.
Companies overseas such as in North America, China, Asia
and Oceania account for 70% of greenhouse gas emissions in
our group of companies in FY2012. We will therefore improve
our activities at Japanese companies and ensure information
sharing within the group.
Kameyama Plant is in the process of acquiring an ISO 50001
certificate which was issued in June 2011 for international
standards in energy management systems. Kameyama Plant
kicked off this project in March 2012 and completed its
management review in March 2013. They are expected to
obtain the certificate in FY2013. Our plan is to expand this
project to our group and advance our Energy Management
Systems.
Develop automotive parts that can support the reduction of CO2
Most CO2 is emitted when products are used based on the
amount of CO2 emission at each stage of the lifecycle of
automotive parts. We are always concerned of improving in
safety and comfort when our group of companies develop and
manufacture automotive parts. We also consider our important
theme of “lightweight” and “conserve space” that can contribute
to reducing CO2.
One of our activities in this report was Lightweight Front
Subframe. This activity was called FSW (Friction Stir Welding)
which is the continuous welding of steel and aluminum with the
technology, and we were the first in the world to succeed with
mass production. (See page 7)
Overall management by All-F.tech is well
grounded
“Environmental Visit” that was started in 2011 was completed as all
facilities across the world were visited by the project members. The
know-how that we gained from the Environmental Visit was set as a
benchmark and it was used as a measure for energy consumption.
The 3rd Global Environmental Meeting was successfully
completed in October 2012. We focused on biodiversity and had
a seminar in this term's meeting. (See page 5)
Our proactive approach towards the environment was
evaluated by our main customer, Honda, and we received an
Environmental Award in 2013. This award was created in 2012
and we received the awarded for two consecutive years. We
also received a Development Award at the same time for our
development activity of FSW.
As for quality, we held the 26th “Global Quality Joint
Conference”. With the development of common quality assurance
standards, “G-FQS”, we followed the standard and improved the
level of quality within the group.
Our group is expanding as we have started construction of
plants in Mexico and Indonesia. We continuously evaluate our
activities of environmental conservation and quality assurance
from the view of supply chain and value chain. We always give
consideration to social responsibility such as compliance and
occupational health and safety so as to be responsible in society.
August 2013
Tsuguo Kimura, President & COO
3
Message from President
Company Principle
From a global perspective, we strive to contribute to our society and to improve the quality of life through manufacturing of highest quality products with ambition and sincerity.
Our action
guidelines
■ Compliance with laws and ordinances
We will always give top priority to ethically appropriate actions in all of our activities. We will always comply with the laws and ordinances and the rules, and each of us will act with common sense as a responsible member of society, so as to ensure a high level of legal compliance at the company. ■ Traffic safety
As people engaged in the production of automotive parts, we will always be in compliance with traffic rules, and we will always strive for exemplary safe driving with a readiness to give way to others on the road.
■ Increase in the corporate value
With an understanding that the continued survival of a company relies on the creation of values, we will strive to raise the corporate value as a company winning recognition from the general public, trying to continue securing profit on a long-term basis.
■ Fair business transactions
We will not engage in any unreasonable or irrational business practices and we will not provide benefits or preferential treatment to anyone beyond common sense or generally accepted ideas, always evaluating various conditions based on comparisons in an impartial manner and conducting business transactions that are sound and fair.
■ Compliance with company regulations and rules
With appropriate understanding of the purpose of establishing the company regulations and rules, which have been established for ensuring a working environment in which every one of the associates can work together with equal rights and opportunities, we will always act in compliance with these company regulations and rules. ■ Conservation of the environment
Based on an understanding that the Earth is an invaluable asset to the whole of humankind, we will strive to minimize, and ensure optimum disposal or treatment for, any waste related to manufacturing, and to utilize natural resources and energy in more efficient ways.
■ Information and public disclosure of
information
We will make clear the distinctions between private or confidential information and the information to be disclosed to the public, and we will strive to provide accurate information that is useful to our customers, and to disclose information that should be made public in a timely and appropriate manner.
Environ-mental principle
F.tech aims to be an environmental forerunner in the automobile industry and is fully committed to building a low-carbon, nature-rich future by deepening the awareness of global environmental issues amongst each and every one of its employees and actively enforcing ongoing environmental conservation activities across the entire spectrum of its corporate activities.
Basic policies
● Reducing environmental impact through product lifecycle
● Reducing CO2 when a vehicle running by reducing its weight
● Conduct reservation of resources and energy in all business activities
● Continue to produce zero waste in all business activities
● Comply laws and regulations of environment
● Conduct continuous improvement of Environmental Management System and prevent pollution
● Set environmental purposes and objectives and review regularly
● Develop environmental persons
● Disclose environmental information related business activities
4
Company principle / Action guidelines / Environmental principle & policies
TOPICS 1 Biodiversity initiative
Biodiversity is a connection with living creature’s
rich characters. Lives on earth have individual
characters and they support each other either
directory or in-directory. There is the degree of
variation of life and that can refer to genetic variation,
species variation or ecosystem variation within an
area, biome or planet. In the Millennium Ecosystem Assessment* it stated that “ecosystem degradation is progressing rapidly and extensively”. To protect sustainable ecosystem and biodiversity is an important task as the climate changes. We at F.tech group are one global company and to tackle these issues is our duty.
*Millennium Ecosystem Assessment – released in 2005, is an international synthesis by 1360 of the world's leading biological scientists from 95 countries that analyzes the state of the Earth’s ecosystems and provides summaries and guidelines for decision-makers.
Biodiversity initiatives as a whole group
F.tech group has started biodiversity activities such as
conservation of bird habitat and tree planting in North
America, cleaning rivers in the Philippines, etc. The Global
Environmental Conference was held to have better and
deeper understanding of biodiversity, and to review all
aspects of environmental activities in the group, we can
expect future environmental preservation activities with a
wide view.
In order to protect nature, we will revitalize biodiversity
preservation activities in on a global scale.
Biodiversity Seminar F.tech group started "Global Environmental Meeting" in
2009 with the goal of sharing effective practices at each
company and leveling energy consumption within the group.
At the third conference held in October 2012 we had a
seminar for biodiversity so as to have a better understanding
with Mobilityland Corporation which is one of the Honda
group of companies. The seminar was held at Hello Woods of
Twin Ring Motegi, and Mr. Koichiro Sakino, the producer of
Hello Woods was invited as an instructor.
Mr. Sakino introduced activities of biodiversity at Hello
Woods. He took us into the forest where they have been
trying to preserve some species. This activity was to replace
Sawara Cypress with oak. We learned that different species
habitats at different altitudes creates biodiversity and makes
a rich flourishing forest.
We also learned that facilities that Honda Motor Co., Ltd
has across Japan have characteristics of each region and
they research what type of living organisms are there and
how many are included in the Ecosystem Assessment.
5
Activity of preservation of biodiversity at each company
F&P (Canada)
Partnered with a local grass roots network
The diversity of life is essential for us to enjoy these simple
pleasures.
For the past 12 years, F&P has partnered with a local grass roots
network that supports and initiates community projects to reduce
pollutants, improve water quality, enhance fish and wildlife
habitats, add native plant diversity and reconstruct natural
streams’ features to help maintain ecological health.
In our ongoing activity since 2006, tree planting, we planted
550 seedlings of white pine, white cedars, nannyberries and
maples into our property.
DYNA-MIG (Canada)
Tree program with Stratford Scout Troop DYNA-MIG partnered up with 3
rd Stratford Scout Troop and
planted 26 coniferous & deciduous trees purchased from our local
Conservation Authority tree program. This activity started in 2011
and since then we planted 79 trees in our property. Combined
with tree planting, the scouts completed a yard waste clean-up
around the pond and field area. The trees planted help reduce
CO2, reduce erosion of the pond’s banks, provides habitat and
cover for the local wild birds. Many wild ducks and Canada
Geese nest in the ponds and this enhance the area for those uses,
while not impacting our use of the land.
To thank the scouts for planting the trees and yard clean-up,
DYNA-MIG contributed a monetary donation to the scout group,
which was used towards Canada’s Scouting Jamboree held in July
2013. A remarkably simple and low cost program, tree planting
contributes to both environment and the local community.
FPMI (Philippines)
Letter of appreciation from Dept. of Environment and Natural Resources
Department of Environment and Natural Resources (DENR) of
Philippines set its goal of tree planting. It is said that 1.5 billion
trees were planted on 1.5 million hectors between 2011 and 2016.
FPMI supported this activity two consecutive years (2011 &
2012). FPMI planted 1540 seedlings in Siniloan, Laguna, and we
received a letter of appreciation from DENR on August 26, 2012.
6
TOPICS 2 Reduced body weight by 25% and reduced electricity consumption during the
welding process by 50%
First in the world! Continuous welding of steel and
aluminum with the FSW technology
Traditionally the FSW is used to weld aluminum and
aluminum, or copper and copper. However, when the
hybrid structured subframe was in mass production we had
to weld two dissimilar metals of steel and aluminum. F.tech
developed the mass production with the FSW technology
for the continuous welding of two different materials.
Controlling the thickness of “intermetallic
compounds” that creates a bonding effect
is the key
First, place a sheet of aluminum onto a sheet of steel and
insert the tool that spins at high speed. The tool then stirs
aluminum and the tip of the tool scrapes away the surface
of steel.
The surface of steel this time is called “newly formed surface”
and there are no impure substances such as an oxide layer.
The stirred aluminum surface also has no impure substances.
When these two metals bond at high temperature without
oxygen, they produce a layer called “intermetallic compound”.
This intermetallic compound acts like an adhesive agent and
joins steel and aluminum.
It is said that this layer of intermetallic compound is thinner
and is better able to provide its strength. So we advanced
the development to pursue the required thickness. In order to
achieve the thickness the surface of steel needed to be
scraped accurately. To develop its control method was the
most important point from the technological point of view.
Why steel and aluminum joined together?
回転
アルミ ス
チール
ツール
撹拌部
金属結合
Joined by metallic bonding produced between steel and aluminum 7
Demand of reduction of CO2 emission is increasing
with environmental perspective when developing a
new model. Therefore, to reduce vehicle weight in
order to increase fuel economy is one of the major
themes. The old Accord model had a metal subframe
with high performance aluminum die cast parts
connecting with the hybrid structuring. The new
model was required to be lighter and highly rigid, so
we needed to improve the hybrid structure.
Therefore, a new welding technology, FSW (Friction
Stir Welding) was adapted.
Merits of hybrid structured front subframe produced by continues welds by FSW
Old model Accord New model Accord
Joined steel & aluminum by bolts
World first
Steel & aluminum joined by continues FSW
■ Major weight reduction
■ Manufacturing energy reduction
-25% -50%
FSW
Control the thickness of ”intermetallic compound”
that has bonding effect was the key
■ FSW equipment
Requires 1/10 footprint than conventional equipment
2
1: Industrial robot
2: FSW welding tool
3: High rigidity C-type welding gun arm
Currently the FSW equipment is installed at F & P America and they
mass produce the subframes. When you stand by the equipment you
can only hear the sound from surrounding welding lines. Watching
noise-less robots make you wonder.
Furthermore, in order to assure its quality a new non-destructive
inspection system was developed and it provides 100% inspection.
Achieving the practical use of this non-destructive inspection system,
enables us to eliminate daily destructive inspection and reduce scrap
cost.
The conventional FSW method required massive, specialized
equipment. However, for new model Accord, the high rigidity C-
type welding gun arm was attached to industrial robots. By this
method it enables to weld a complex shape such as subframe
and saved significant space.
The FSW method uses a rotating tool that stirs aluminum,
therefore, not required shield gas. This means this equipment
does not produce metallic fumes, one of the causes of
occupational disorders.
Required electricity is needed for robot, to rotate tool and for
motor that controls location of welding. The new model was
produced with half the electricity than the old model required.
Also, the equipment requires only motor, so it is very quiet.
With the FSW technology we achieved reducing body weight by 25%
compared to a conventional steel subframe. In addition, electricity
consumption during the welding process was reduced by 50%. We’d
like to utilize this core technology we established for the mass
production of future.
High performance
infrared camera
1 3
Measure difference of heat energy reflection
Proactively active to meet the purpose and goals of 3 companies in Japan
9
Environmental Goals & Results
○: Target achieved, △: Achieved more than 70% less than 100%, ×: Achieved less than 70%, －: Not applicable
*1 Reduction of CO2 emission, reduction of waste by implementing countermeasures; Regardless of amount of reduction is made based on the amount that could be reduced by
countermeasures
*2 LCC: Leading Competitive Countries - To procure parts and/or services from countries that have excellent competitiveness
*3 G-FQS: Global F.tech Quality Standard – Global quality assurance standard is provided within the group to achieve the highest quality
FY2012 Targets FY2012 Results Evaluation FY2013 Targets
- Improvement of CO2 emission basic unit
Examinee: Head office, Kuki plant,
Kameyama plant, Haga T/C
Improved by 7.5% (FY2010) Worsened by 14.1% (FY2010)
Amount of value added was decreased,
therefore did not meet the target. The
policy reviewed for FY2013. X
- Improvement of CO2 emission basic unit by
3% (Compared with FY2010)
All of the facilities: more than
137.4t-CO2 reduced.
Subject resources: electricity, city
gas, LPG, diesel fuel, gasoline,
CO2 gas
All of the facilities: 226.6t-CO2
Manage total amount of energies
All facilities: less than the 58ki usage
Subject resources: electricity, city gas, LPG,
diesel fuel (forklift only)
Kuki plant: reduction of more than
56.6t-CO2
Kuki plant: 79.0t-CO2 reduced
Kuki plant: reduction of more than 38.1t-CO2
Kameyama plant: reduction of
more than 70.2t-CO2
Kameyama plant: reduced 81.8t-CO2
Kameyama plant: reduction of more than
54.9t-CO2
Haga T/C: reduction of more than
10.6t-CO2
Haga T/C: reduced 65.8t-CO2
Haga T/C: reduction of more than 13.7t-CO2
- Reduced waste more than 1% by
implementing countermeasure (compared
with previous term)
Examinee: Head office, Kuki plant
Kuki plant: reduction of more than
502m3 of water usage
Kuki plant: reduced 3,104m3 of water
usage -
Inte
rnatio
nal
Sta
ndard
- Preparation of ISO 50001 certificate Completion of Management
Review of ISO 50001
(Kameyama plant)
Completed Management Review of ISO
50001 (Kameyama plant)
Acquire external authentication for ISO 50001
(Kameyama plant)
Held Global Environmental Meeting - To held Global Environmental
Meeting
Completed
- To held Global Environmental Meeting
Completed
- To held Global Environmental Meeting
Completed
Enhance supply chain management - Perform Environmental Audit for
10 domestic companies
Completed 10 companies
- Perform Environmental Audit for 10
domestic companies
Visited 6 companies and 6 companies
completed self-evacuation
- Grasp supply chain GHG data
Completion rate: 100%
Chem
ical
Substa
nces
Conta
ined in
Pro
ducts
Pro
gra
m
Establish LCC assurance system*2 - Standardization of G-FQS*3
Completed
- Standardization of G-FQS
Completed
- Implementation of training for chemical
substance management
Completed 5 associates
All-F
.tech O
vera
ll
Managem
ent
Item
Pre
ventio
n o
f glo
bal w
arm
ing
- Reduced CO2 emission more than 1% by
implementing countermeasure (compared
with previous term) *1
Examinee: Head office, Kuki plant,
Kameyama plant & Haga T/C
3 Japanese plants to be a leader to improve the "All F.tech System"
10
Environmental Middle Term Plan
）2
展 開 施 策 計画
実績
2011 年 2012 年 2013 年
地球温ベン暖チ化マのー防ク展止開
計画 ベンチマーク設定 効率改善 高位平準化
実績 ベンチマーク設定完了 効率改善実施 －
評価 ○ ○ －
サプライチェーンを含む 温
室効果ガスの把握
エネルギー原単位の改善
計画 把握率 80% 把握率 90% 把握率 100%
実績 把握率 84% 把握率 91％ －
評価 ○ ○ －
計画 ５% 改善＇ 2010 年比（ 7.5% 改善＇ 2010 年比（ ３% 改善）1＇ 2010 年比（ 実
績 2.9% 改善＇ 2010 年比（ 14.1% 悪化＇ 2010 年比（ －
評価 × × －
認証国取際得規格の
ISO 50001 の認証取得
計画 検討 システム構築 認証取得
実績 検討完了 システム構築完了 － 評
価 ○ ○ －
計画 システムの見直し ISO 50001 統合 認証継続
ISO 14001 の最適化
統括オ管ー理ルエフテックの
海外子会社環境 VISIT ）3
の実施
実績 システムの見直し完了 ISO 50001 統合完了 － 評
価 ○ ○ － 計
画 海外子会社 FMTL 弱点領域
実績 海外子会社８拠点完了 FMTL 完了 － 評
価 ○ ○ －
計画 震災により開催中止 国内開催 国内開催
世界環境会議の定着
の管製理品含有化学物質
オールエフテック管理体 制
の標準化
実績 － 国内開催完了 －
評価 － ○ －
計画 運用 改善 定着
実績 運用開始 改善完了 －
評価 ○ ○ －
計画 標準化 運用 G-FQS 発行
LCC 展開保証体制の構築 実績 標準化完了 運用開始 －
評価 ○ ○ －
The Middle Term Plan which started in 2011 ended in FY2013.
In the Middle Term Plan we have five main programs;
“Prevention of global warming”, “Obtain international standard
certificate”, “All-F.tech Overall Management”, “Develop
environmental friendly products*4
” and “Chemical Substances
Contained in Products”.
As for Prevention of global warming program for
FY2012, we set the goal based on the amount of value-
added. However, the market shifted to small cars and as a
result the amount of value-added was reduced. Therefore, we
did not meet the goal. We reset the goal by changing from
value-added basic unit to product weight basic unit for FY2013.
We ensured that activities in FY2013 were steadily
implemented to strengthen the foundation for the new midterm
plan that will start in 2014.
*1 Reset the goal from based on the value-added basic unit to product weight basic unit *2 ISO 50001: It is the international standard for organizations to integrate energy management into their overall efforts to improve quality and environmental management. It was released by ISO in June, 2011.
*3 Environmental Visit: It is the environmental management system of F.tech Group. It is to evaluate compliance, ISO 14001 management status.
*4 Development of environmentally friend products continues to be our critical item for the Mid Term Plan (FY2011-FY2013), however, from a confidentiality point of view we will not disclose the information.
Plan
Actual
Plan Set benchmarks Improvement of OEE High equalization
Actual Completed setting benchmarksImplemented of OEE improvement
activities-
Evaluation -
Plan Completion rate: 80% Completion rate: 90% Completion rate: 100%
Actual Completion rate: 84% Completion rate: 91% -
Evaluation -
Plan Improve by 5% (compared with 2010)Improve by 7.5% (compared with
2010)
Improve by 3% *1 (compared with
2010)
ActualImproved by 2.9% (compared with
2010)
Disimproved by 14.1% (compared
with 2010)-
Evaluation X X -
Plan Examination Develop system Obtain the certificate
Actual Completed examination Completed development of system -
Evaluation -
Plan Review the system Combined with ISO 50001 Continue to be certified
Actual Completed review of the system Completed combining with ISO 50001 -
Evaluation -
Plan Oversea affiliates Environmental Visit to FMTL Weak area
Actual Completed 8 oversea affiliates Completed -
Evaluation -
Plan Held overseas Host it in Japan Host it in Japan
Actual Cancelled due to the earthquake Completed -
Evaluation - -
Plan Run the system Improvement Continuance
Actual Completed Completed -
Evaluation -
Plan Standardized Run the system Issuance of G-FQS
Actual Completed Completed -
Evaluation -
All-F
.tech Overall M
anagement
Implementation of Environmental Visit*3 to
overseas companies
Establishment of Global Environmental
Meeting
Chem
ical Substances C
ontained in
Products P
rogram
Standardized All F.tech Management System
Establish LCC assurance system
FY2011 FY2012 FY2013
Benchmarking
Improvement of energy basic unit
Prevention of global w
arming
Grasp of GHG data including supply chain
Critical
itemsItem
International Standard
Obtain ISO 50001*2 certificate
Optimization of ISO 14001
11
Reducing carbon footprints from development to production
certification.
Environmental Middle Term Plan
INPUT F.tech Group OUTPUT
Raw material (only 3 plants in Japan, Japanese affiliates
and related companies)
Steel
79,503 ton
Aluminum
5,974 ton
Plastic
52 ton
Overall group
Waste 4,763 ton
Landfill 1,588 ton
Water
689,000㎥
Energy
Electricity
151,369,000kwh
City gas
4,613,000㎥
LPG
2,739 ton
R&D
↓
Production
CO2
CO2
Natural gas
2,438,000㎥
Gasoline
24 kℓ
Diesel oil
112 kℓ
Kerosene
216 kℓ
Stamping/ Welding
Paint/ Assembly
91,145ｔ-CO2
Gasoline
317 kℓ
Diesel oil 36 kℓ
Gasoline
5 kℓ
Diesel oil
1,716 kℓ
Company cars
Transportation
Customer (OEM)
CO2
CO2
CO２
834ｔ-CO2
CO２
4,534ｔ-CO2
Users
・Amount of material combines 3 facilities and affiliates in Japan. Other amounts are combined of the F.tech Group.
・CO2 emission in OUTPUT was calculated multiplying the amount of energy consumption in INPUT by CO2 conversion factor.
・Referred calculation method of CO2 issued by Ministry of Economy, Trade and Industry and WRI/ WBCSD “The Greenhouse Gas Protocol”
・Power consumption in Japan was calculated based on the latest factor of each power company
・Date period is 04/2012 – 03/2013
・Numbers shown are round off
12
All of our production facilities obtained ISO 14001
certification
All-F.tech Environmental Management System
At F.tech we recognized environmental issues as critical items
to manage, so we started our action to obtain ISO 14001
certificate in 1998. Production facilities located overseas also
obtained ISO 14001 certificate to work together to build a F.tech
Environmental Management System.
Organization
We started All F.tech Environmental Management System in
2008. The president of each overseas facility is in charge of the
system and placed an associate in charge who organized its
system.
Compliance
Laws and regulations of environment are diverse in each
country and region and they are enormous. Some facilities
overseas have a contract to make sure that laws are observed.
Domestic facilities hold monthly environmental meetings to
confirm the progress of action, and once a year we check if laws
and regulations are observed.
In 2012 we introduced an electronic manifest system into 3 plants in
Japan to improve our law management of waste disposal.
Environmental training
The company provides the ISO 14001 Basic Course as a
requirement and many employees take it. Also, environmental
seminars and internal auditor training courses are provided to
educate employees. Moreover, we invited an instructor from The
Energy Conservation Center for energy conservation for the 3rd
Environmental Meeting.
Overseas facilities also have training as well. The facility in
China provides environmental training to all employees and
invites an external instructor to provide study sessions. In the
Philippines, Improve Environmental Awareness Program was in
place. They implemented Proper use of energy consumption
patrol and posted its results on the bulletin board. They also
created objects and bench made by packaging waste and
donated them to local schools.
■エフテック環境管理体制 社 長
環境担当役員＇生産本部長（
世界環境会議 JPN事務局
※オールエフテック統轄管理
アジア・大洋州３拠点
拠点長責任者
中国２拠点
拠点長責任者
北米６拠点
拠点長責任者
国内７拠点
環境管理責任者 ・環境管理実施責任
者
・実務担当者 ＇現地スタッフ（
日本人駐在者 ＇サポート（
・環境管理実施責任
者
・実務担当者 ＇現地スタッフ（
日本人駐在者 ＇サポート（
・環境管理実施責任
者
・実務担当者 ＇現地スタッフ（
日本人駐在者 ＇サポート（
・サイト責任者
・環境管理実施責任者
・環境管理推進責任者
関連部門 関連部門 関連部門 関連部門
※国内７拠点については国内子会社・関連会社を含みます。
Activity for obtaining ISO 50001 certificate in 2013 <Kameyama Plant>
At Kameyama plant, they kicked off a project in March 2012 to be certified ISO 50001 that became international standard in June 2011. ISO 50001 is also called energy management system, and it was issued considering the present energy conditions in the world. An Energy Management System was introduced into Kameyama plant and they monitor the consumption of electricity, city gas, LPG, air and welding gas for 24/7. By utilizing the ISO 50001 system it enables them to
develop a systematic energy conservation program and helped organize steps to analyze data, goal planning and confirmation of effect. They also developed working groups from the beginning and increased morale as all of department worked together.
By being certified of ISO 50001 in FY2013 we will accelerate the activity of CO2 reduction to our group of companies overseas.
ISO 50001 Kick-off
Environmental Management
13
Environmental loads are grasped by all of companies
■ Emission of greenhouse gas
( CO2)
120,000
100,000
80,000
t- CO2
92,905
81,752
94,485
83,948
96,513
中国 15％
■2012 年度内訳
アジア・大洋州 9％ 日
本 31％
60,000
40,000
20,000 北米 45％
0
2008 年
2009 年
2010 年
2011 年
2012 年
■ Japan ■NA ■China ■Asia, Oceania
* Data of greenhouse gas was collected from energy used at factory, research institution and transportation.
* The data was tracked back and revised
* "Japan" including Kuki plant, Kameyama plant, Haga Technical Centre and other affiliate companies' data.
* Referred calculation method issued by Ministry of Economy, Trade and Industry and WRI/ WBCSD “The Greenhouse Gas Protocol
* Japanese domestic electricity is based on the latest information provided by each power company.
* Reported values is round off it to first decimal places
■ Amount of use of water 800 700 600 500
千m3
592
504
583
543
689
■2012 年度内訳
アジア・大洋州 22％ 日
本 16％
400
300
200
100
中国 25％ 北米 37％
0 2008 年
2009 年
2010 年
2011 年
2012 年
■ Japan ■NA ■China ■Asia, Oceania
"Japan" including Kuki plant, Kameyama plant, Haga Technical Centre and other affiliate companies' data.
* Reported values is round off it to first decimal places
■ Amount of waste 6,000
5,000
4,000
ton
5,498
4,591
5,082
4,077
4,763
中国 19％
■2012 年度内訳
アジア・大洋州 7％ 日
本 18％
3,000
2,000
1,000 北米 56％
0 2008 年
2009 年
2010 年
2011 年
2012 年
■ Japan ■NA ■China ■Asia, Oceania
"Japan" including Kuki plant, Kameyama plant, Haga Technical Centre and other affiliate companies' data.
* Reported values is round off it to first decimal places
■ Amount of landfill 1,800
1,600
ton
1,550
1,517
1,567 1,588
45％
40％
■2012 年度内訳
アジア・大洋州 3％
1,400
1,200
1,000
800
600
400
200
0
28％
1,138
2
5
％
30％ 38％ 33％
35％
30％
25％
20％
15％
10％
5％
0％
中国 22％ 日本 15％
北米 60％
2008 年 2009 年 2010 年 2011 年 2012 年 ■ Japan ■NA ■China ■Asia, Oceania Landfill rate (%)
"Japan" including Kuki plant, Kameyama plant, Haga Technical Centre and other affiliate companies' data.
* Reported values is round off it to first decimal places
All-F.tech Environmental load reduction activity
14
Continuously working on the regulations for chemical substances that are expanding globally
Chemical substances management seminar
Enhance supplier control
At F.tech group we developed a system that manages the
regulations of chemical substances that are contained in
products and customer’s requirements, and we also
implemented IMDS surveys.
It is important to work together with suppliers for the Chemical
Substances Contained in Products Program. We therefore
developed and distributed its survey manuals and standards.
However, the program has not sunk in yet as there were some
mistakes and lack of explanation of the program.
So we promoted the following two activities to enhance
suppliers control in FY201.
1 Supplier Environmental System Audit* We performed the Environmental System Audit follow up last
year to 6 suppliers located in the Kanto region, Kyushu region
and Tokai region. Their data was overall well organized and each
of them understood how to do the audit.
Environmental audit
2 Chemical substances management seminar for suppliers
We held a seminar for suppliers located in Kameyama and
Kuki for chemical substance regulations, how to survey and case
study. 41 people from 31 companies participated.
During the seminar we exchanged concerns, method of survey
and opinions. It was a very informative seminar and the
information will be utilized in the future.
Future Activity
We will expand our activity to facilities overseas in the future.
First step we took in FY2013 was setting common rules within the
group for the Chemical Substances Contained in Products
Program in G-FQS** and applying the rules. This way we can
strengthen the response of regulations for chemical substances.
*Environmental System Audit: the representatives from F.tech Quality Assurance Division and Purchasing Division visit suppliers and confirm their chemical investigation system. ** G-FQS: Global F.tech Quality Standard
Chemical Substances Contained in Products Program
15
Started operation of Global F.tech Quality Standard System*1
We exercise within the group; “Prevent defects from happening. Take quick actions. Go back to the original and improve it”
In order to achieve a high level of quality at all companies while
we facilitate our business of Sales, Development, Production and
Purchasing globally, we at F.tech set common quality standards
“G-FQS” in FY2012.
For FY2013, we verified the “G-FQS” based on the actual
work, and included required item from the TS*2 and the
customer's requirements. Also, by including manufacturing
know-how and preventative know-how for defects the standard
become more specific and effective. With these activities the
system was completed and all facilities within the group use
these integrated rules.
Enhance Change Point Control and improve troubles caused by human error
"Visualization" and "4M*3 Change Point Control" that we have
being working with since 2009 showed that troubles caused by
human error were on the increase.
Therefore this fiscal year we enhanced our efforts in "Man
Change Point Control".
More specifically we focused on reducing troubles by providing
training for new associates, transferees and anyone who had a
long absence.
26th Global Quality Joint Meeting
The 26th Global Quality Joint Meeting was held on May 24
and 25 of May in Kuki, Saitama. During the meeting we
presented quality performance from each company and shared
improvement measures. We all had refreshed minds to achieve
high quality levels. The participants toured our affiliate company
Reterra to look at environmental technology, aluminum die cast
technology which is leading the way in the "lightweight" product
field.
Global Quality Joint Meeting
Functions of G-FQS 人の変化点管理の強化
M th d 方法
*1 G-FQS: Global F.tech Quality Standard
*2 TS: ISO / TS16949 is international standard for quality management system
*3 4M: Man, Machine, Method and Material. By controlling these 4 items to prevent defects.
Quality Assurance
16
品質保証の取り組み
Inspection and improvement for "Safe work environment" in the group
At F.tech we set the goal of "Zero Lost Time" for the 11th Midterm
Plan (FY2011 - FY2013). Since 2010 nine facilities overseas
were checked periodically for their safety by using the integrated
control index . This fiscal year was the second year and it is time
to review countermeasures as necessary.
In FY2012, safety inspection was performed at 7 overseas
facilities (F&P, F&PA, DYNA-MIG, F&PG, FPMI, FEGQ and
FMTL)* based on the Safety Credibility Inspection Manual.
FMTL safety audit findings (Stamping)
Enhanced safety from the experience
of flood
In the North America region (Canada, USA and Mexico), Safety
Meetings are held twice a year (April and October). By
exchanging information between safety representatives the safety
countermeasures were shared in a speedy manner and prevented
reoccurrence and reduced risks. Therefore, we will continue this
activity.
Facilities in new developing countries shared the
countermeasures that had already been implemented at other
facilities and improved safety awareness of associates and their
work environments.
In Japan, four affiliated companies (FEG, QFT, Reterra and
Johnan Manufacturing) were inspected using the Safety
Credibility Inspection Manual.
As for the fire protection, it has been our continuous theme
since last year. A standardized welding spatter shield plate was
installed at all facilities to prevent exhaust duct fire.
In FY2012, each facility was checked based on the results
from the previous term, and the progress of the findings. The
remaining items were followed-up on to solve the issues.
The safety inspection using the Safety Credibility Inspection
Manual states that you can inspect the production site with
different eyes, and shared safety countermeasures with other
facilities. We will continue to improve the safety environment and
improve the skills of safety supervisors.
* Facilities in China, FTZ and FTZ were not included the safety inspection for various reasons.
As for FMTL in Thailand, after recovered from the flood they were inspected thoroughly
every 3 months.
1st Annual Kuki Traffic Safety Seminar
November 25, 2012, F.tech Traffic Safety Committee and
Honda Affiliated Companies Industrial Accident Prevention
Committee Saitama Branch held the 1st annual Kuki Traffic
Safety Seminar. Eighty two people (25 families) participated on
that day. The participants had a lecture about traffic rules and
they also learned the dangers of accident through demonstration.
Saitama Police's mascot Poppo and female motor officers came
to support the event. The participants enjoyed hand-on activities
to learn traffic safety.
The participant's feedback was positive as "Please hold this
seminar every year" (parent) and "I will watch out for cars"
(student). The committees decided to have a second seminar.
(Schedule to be held on October 27, 2013)
Instructor explaining the dangerous of large truck making a turn
Health and Safety
17
TOPICS
Global Activities
JAPAN
Kuki Plant
Cooling water circulation pump with high efficiency IPM motor
At Kuki Plant, they worked on electricity reduction for the cooling water circulation pump
which was consuming a fair amount of electricity because it was running at all times. They
installed a high efficiency IPM motor that had a permanent magnet and advanced technology.
As a result, CO2 was reduced by approximately 6t-CO2 annually.
The dimensions of this high efficiency IPM motor were the same as the existing motor, so
it was easy to install. Therefore, they are planning to install similar equipment in the Kuki
Plant.
Kameyama Plant
Changed from mercury bulbs to LED in Stamping. Improve work environment by applying heat shield coating
At Kameyama, they are continually working on conserving energy. In the past they
harvested lights from the skylight to mange turning of mercury lights on/off automatically,
and also lighting controls were installed in the tent warehouse to eliminate waste.
In FY2012, Kameyama replaced some mercury bulbs in the Stamping area with LED
lighting. They maintained the luminance by 76 1000-w bulbs in the Stamping area, but
reduced electricity consumption by one third while maintaining the same luminance by
replacing 16 light fixtures with LED. With this activity they were able to reduce the electricity
by 56,800kwh annually. Moreover, they are planning to replace the remaining 60 bulbs with
LED in FY2013.
The Stamping area in Kameyama does not have an air conditioner and therefore the place
gets very warm in summer. They therefore worked on the issue by applying a heat shield
coating on the roof. With this coating they were able to reduce the roof temperature when it's
sunny by 20 degrees. Feedback from associates was also positive as they felt better than
past summers.
They also turned off street lights surrounding the plant for weekends to reduce power
consumption, utilized the heat from the compressor for winter, and reduced weekend's
standby energy for gas heat pump by using their energy management system. They will be
continuously working together on energy conservation to be the Green Factory in the group.
Haga Technical Centre
Conserved energy of hydraulic power units to reduce CO2 by 5% from the previous term
At Technology Development Block at Haga, they focused on reducing energy that was used
for the hydraulic power unit. The hydraulic power units had high proportion of energy
consumptions at Haga, so they thought they could reduce power consumption significantly.
They started by checking the correlation between the test conditions and the capacity of
test equipment. The hydraulic power units were operated at certain speed of motor and the
units worked at full capacity at the rated pressure. They therefore reduced the pressure
where it was possible and reduced power consumption by reducing the load on the motor.
They also were able to disable one of the twin motors that some of the hydraulic power units
had, because depending on the testing descriptions, only one motor was needed.
By combining these two countermeasures together, they were able to reduce power
consumption by 150,000kwh and CO2 emission by 50t-CO2 annually in FY2012.
(Approximately 5% of CO2 emission was reduced overall in Haga compared to last term)
Circulation pump with high efficiency IPM motor
mercury bulbs
16 LED bulbs
Changed from mercury bulbs to LEDs in Stamping area
▲ After heat shield coating ▲ Before coating
油圧源圧力調整
disabled one motor of two
18
Kushu F.tech Inc.
Sun block window film
At Kushu F.tech, they installed sun block window film to the administration building and
cafeteria in the summer 2012. Before the installation the temperature of the room was high
due to the sunlight coming through the windows. Therefore, they frequently used an air
conditioner and as a result the electricity expense was high. By installing the window film, the
room temperature was reduced by 1 to 3 degrees and the electricity expense was also
reduced by 8 to 32 %. There was another benefit in terms of security by putting this film on
the inside of building it was difficult to see in from outside.
Reterra Co., Ltd.
Filtration, purification, and reusing cutting fluid
At Reterra, they operate cutting machines such as machining centre, tapping centre and
NC lathe for aluminum die cast for 24 hours. As one of the activities to reduce waste, they
worked on reducing cutting fluid.
In the past they used 8000 liters for topping off the fluid and replacing it annually. As well,
the spent 2.7 million yen to purchase the fluid and 50,000 yen for waste treatment.
Therefore, they make a "filtration system" in-house to reduce the purchase amount of cutting
fluid and to recycle the cutting fluid.
They maintained the ph of cutting fluid after the project, and reduced the fluid by 1,600
liters, saving the purchased amount by 540,000 yen. Waste treatment was no longer needed,
so they saved approximately 600,000 yen annually. They will be promoting "Recycle" and be
proactively working "Reduction of energy consumption" to reduce CO2 emission for the future.
Johnan Manufacturing
Emergency stockpile for employees and community
Recently, natural disasters such as earthquakes, heavy rains and tornados occur frequently
in Japan, including the Great East Japan Earthquake. There is a prediction that the Nankai
Trough Quake will occur in the coming years. It has become more important to prepare
against such disasters.
At Johnan, they were aware of the importance of preparing for disaster, so they installed an
emergency stockpile storage in FY2012. When a disaster occurred it would take a few days
to receive disaster assistance from the government or local governments due to damaged
infrastructures. Therefore, they stockpile 5days worth of emergency supplies so that
employees and their families can survive a disaster.
Mainly, basic emergency goods such as water, preserved food, medical goods and hygiene
products are stockpiled. The goods inside the storage are considered age specific from
toddler to elderly and some of them are environmentally friendly products. Johnan thinks that
preparation for a disaster is part of their corporate social responsibility and is a community
support activity.
sun block window film
Cutting fluid applied (circulated)
Filtration system made themselves
Stockpile storage for emergency
TOPICS
Global Activities
ASIA
20
FPMI
Environmental Award from Honda Cars Philippines Inc. (HCPI)
At FPMI, reduction of CO2 is included in their business plan and this term their goal was to
reduce 1% annually. In FY2012, they installed a timer for lights to the production floor and
locker rooms, installed LED lights for the inspection table in the plastic plant, and changed the
Quality Assurance office's light fixture's covers to transparent covers. They also worked on
tree planting, reusing waste water and waste materials, and conservation of resources. FPMI
made a presentation of CO2 reduction activities to HCPI, HPMC*, and ASH* on March 11,
2013 when they visited FPMI. As a result, FPMI received a Certificate of Appreciation from
HCPI on April 12, 2013.
* HPMC: Honda Parts Manufacturing Corp.
* ASH: Asian Honda Motor Co., Ltd.
FMTL
Reduced use of compressor of stamping, and improvement of lightings
At FMTL, each department is always aware of reduction of electricity consumption. At
Stamping, they use air blow to clean metal pieces, but they changed the material of the scrap
chute to a smooth material and also changed its angle. As a result, they stopped the use of
air blow and reduced power consumption by 4921kwh per month. As for lightings, they
changed from 450w bulbs to 250w bulbs with light-reflecting surfaces. By changing the bulbs
they were able to reduce electricity by 683kwh per day while maintaining luminance.
Currently they are examining if the light-reflecting surface can be used for 150w bulbs.
FTW
HCPI Environmental Award ceremony
Before After
LED lightings in production area
At FTW, they used general lightings for the production area. The general lightings used
more electricity compared to LED and were replaced frequently due to thier short life.
Therefore, FTW changed the lightings to LED that were installed in high places such as the
Stamping area, high rack area and Quality Control department area. LED's product warranty
period is 5 years, so they were able to reduce the amount of waste. Also, they installed
sensors to 18 LED fixtures out of 36 in the high rack area as it has less traffic. As a result of
all activities, the electricity was reduced by 131,000kwh compared to last term and CO2 was
reduced by 118t-CO2. Their activities for the environment were evaluated by their major
customer, Dongfeng Honda Automobile Company and they received an Award for Excellence
for the Environment.
sensor for high
rack area
LED lighting
FTZ
Energy conservation by reusing waste heat from paint
改善後
At FTZ, they promoted the activity of "Reusing of waste heat from painting". This activity
was to reuse waste heat from the paint incinerator to the hot water tank, paint oven, and
sludge oven so as to reduce industrial waste and the consumption of natural gas.
1) Installed a temperature control device and heat exchange pipe to warm water tank.
2) Installed duct for recycling heat, air volume valve and filter to paint oven.
3) Put heat storage ceramics into sludge drying oven that enables it to reuse the waste heat.
With these activities they were able to reduce natural gas consumption by 5% or 30,000m3
annually and saved 1,470,000 Chinese yuan*. Also, the amount of water contained in
sludge was reduced from 70% to 20%, and the cost of waste treatment was reduced by
100,000 Chinese yuan* annually.
* 1 yuan = 16 yen (As of August 2013)
19
TOPICS
Global Activities
NORTH AMERICA
DYNA-MIG
Received Award of Excellence from Stratford Festival Hydro
On March 12, 2013, DYNA-MIG received an Award of Excellence from local power supply
company, Festival Hydro, for a company that contributed to reducing electricity consumption
during the period of June 2011 to December 2012.
DYNA-MIG was the only manufacturing company out of 5 other local companies that was
awarded this time. Their activities of changing pumps and fans to an inverter system and
installing high efficiency lighting were evaluated. They are continuously participating in
recycling activities such as the Cigarette Waste Brigade and the tobacco recycling program
and, they are planning to change cleaning products and lubricant oil to environmentally and
human friendly products.
F&P
Compressed Air Leak Detection Project
At F&P, a GF circle team implemented an air leak investigation. The team found out that
20 -30 % of compressed air was leaking and it was resulting in inefficient equipment
operation and financial waste. Therefore, they installed a sensor. The sensor is a state of the
art electronic device that detects small leaks, as well as measures air consumption on high
capacity compressed air systems. The sensor was installed on a pilot welding cell. The
sensor detected the machine to have a 42 CFM* air leak, which results in electrical savings
of $5,800 per year. It was also noted that the air leaks in plastic tubing were located close to
the weld locations on the weld fixture. It was determined that the air leak was not only
increasing the electrical consumption, but also affected part quality by causing weld porosity.
The team is continuing with the testing and will be recommending the technology for other
equipment.
*CFM: Cubic Feet per Minute
F&PA
ISO 14001 audit was completed with zero audit finding
At F&PA, they completed the ISO 14001 audit without any findings. Associates were
involved in all aspects of the audit and showed their responsibility to follow the
environmental rules. The auditors told them that there were only 4 companies that didn't find
any their concerns.
Assocaites worked each activity by themes and added containers for recycling. This was
not only for segregating garbage, but increasing awareness of reducing waste for associates.
Also, when expanding their parking space they had to cut trees down. However, they
replanted more than they cut. Moreover, they reduced chemical usage by 5% by introducing
new waste water treatment system.
F&PG
Quick repair by using "Air Leak Map"
At F&PG, they found out that their cost in the production area was the highest due to air
leaks. Therefore, they started a cost reduction plan by using an air leak map in FY2011.
The air leak map was posted in production areas. When an air leak was found the
associate identified where the leak was on the map. For example, when an air leak was
noticed at Welding Pilot Lower Arm B cell, they drew a circle with a marker provided around
the cell location. Production tech are responsible to view the air leak map everyday and
repair the leak in their area as soon as possible. With this activity they were able to reduce
25 ton/10,000 units of CO2 in FY2012.
Stratford Festival Hydro Award Ceremony
Weld slag that
contributes air leak
Sensor installed on
main pipe in welding
cell
Recycling containers
Air Leak Map
22
Global and systematic approach to our system
Corporate Governance
F.tech has responsibilities to meet shareholder’s expectations
while focusing on employees, suppliers and the local communities.
Also, we must set long term goals for the company and maximize
revenues for the shareholders as a principle of Corporate Governance,
while organizing a business management structure (Board of Directors,
Board of Auditors) and a global structure that can work at compliance
and risk management.
In order to monitor our business operation in an objective manner
we have created an Operating Officer system while external auditors,
Board of Directors and Board of Auditors monitor and audit. The term
of Board of Directors is one year to accommodate a volatile business
environment.
The Board of Directors consists of 7 directors. They make
decisions relating to critical business matters.
The Board of Auditors consists of 3 auditors (2 are external
auditors) and each auditor attends Board of Directors Meetings,
conducts investigation of financial activities, and controls business
operations based on the auditing policies established by the Board of
Auditors.
We have 4 Divisions and 2 Offices and each section has a
director. The Management Meeting consists of 7 directors and a total
of 12 members of Senior General Managers and General Mangers.
They are responsible for discussing business matters to be decided
upon by the Board of Directors.
In addition, major domestic plants and overseas plants have an
Operating Officer to judge critical matters in a speedy and efficient
manner.
Internal Control
A department in charge of internal control recognizes the risks
that are related to its major operations, chooses a responsible person
and holds meetings to prevent a loss from happening. Also there is an
independent audit department which is under the direct control of the
president. It has four internal auditors and they audit each
department’s operations.
As of March 31, 2013, we have issued “Internal Control Report”
stating that our internal control related to financial report is valid.
Corporate Ethics Committee
In October 2004 we established “Corporate Ethics Committee”
(Chairman: Director & Senior Managing Operating Officer, also Compliance
Officer) to confirm our compliance situation and develop policies. Also we
established “Corporate Ethics Kaizen Window” to protect a whistle-blower
and to be aware of corporate ethics.
In November 2004, we developed “Our Action Guideline”, and “Rules &
Regulations of Compliance” in June 2006 to improve corporate ethics. In
2010, we revised “Rules & Regulations of Compliance” for employees for
ease of understanding and then distributed it to all employees.
Risk Management
F.tech Group developed “Risk Management Standards” in June
2006. We have a system that if the following situations occurred the
emergency headquarters headed by the president will be set up
immediately when;
- Significant loss occurred to customer
- Serious labour accident occurred
- Extremely important information was leaked related to
business operation
- Major supplier went bankrupt
- Significant loss caused to customer due to disrupted computer
system
- Breach of law or received administration penalty
- Majority shares were cornered
- Significant damage caused by fire, earthquake, flood, etc
- Major event occurred and the company is unable to continue
its business.
At any normal time we assign a Risk Management Officer in Corporate
Ethics Committee to overview the company, and each division has a
checklist to verify its activities periodically. The checklist is audited by
internal auditors.
Corporate Governance/ Compliance/ Risk Management
21
社 名
In accordance with our fundamental principles “Respecting People,” “Challenging Spirit” and
“Making Profits,” we will expand our business globally and aim for “Customer Satisfaction No.1.” We
will produce and supply automotive parts that comply with customer requirements and laws in
designing and development, and striving to achieve high quality.
F.tech Inc.
Head office
19 Showa-numa, Shobu-Cho, Kuki, Saitama Pref.
Established
July 1, 1947
Capital
¥2,677 million
President & COO
Tsuguo Kimura
Employees (consolidated)
5,893 (As pf March 2013)
Business activities
Development, design, manufacturing and sales
of automotive parts, and related dies,
machinery and equipment, etc.
Main customers
Honda Motor Co., Ltd., Nissan Motor Co., Ltd.,
Suzuki Motor Corp., General Motors Corp.,
Isuzu Motors Ltd., Toyota Motor Corp.,
Daihatsu Motor Co., Ltd., Mitsubishi Motors
Corp., and others
Company Profile
Consolidated sales (million yen)
Sales by segment (million yen)
Employees by segment
Japan N America Asia
株式会社 エフテック 発 行 ： 株式会社エフテック
〒346-0101 埼玉県久喜市菖蒲町昭和沼 19 番地
問 合 せ： 株式会社エフテック
生産本部 品質保証ブロック 品質保証課 環境システム係
TEL 0480-87-1162 FAX 0480-85-4406
E-mail : [email protected]
2013 年9月発行 次回発行 2014 年9月予定
１１部部ああたたりり CO2排出量
445.0 g-CO2
1,400部作成のための 総排出量 623ｋ
g-CO2
この印刷物は、日本水なし印 刷
協会 、一般社団法人 日 本 カー
ボンオフセットを通じて、 印刷物
作成でのCO2 排出量 をオフセッ
ト＇相殺 （すること で、地球温暖
化防止に貢献し ています。
この印刷物は、適切に管理された森林で生産されたことを示すFSC®森林認証紙を使用。 植物
性大豆インキを用いて、有害物質を使用・排出しない「水なし印刷」で印刷しています。
