Eight Toyota manufacturing facilities have collectively reduced their energy consumption 24% from the baseline warranting recognition from the EPA.

The U.S. Environmental Protection Agency (EPA) has recognized eight Toyota manufacturing sites in North America for achieving a ten percent reduction in energy intensity through its ENERGY STAR Challenge For Industry program. Collectively, these eight sites have reduced energy intensity by nearly 24 percent from baseline.

Energy intensity is measured relative to efficiency improvements in process and equipment.

The ENERGY STAR Challenge For Industry program is only awarded to individual industrial sites. To gain recognition, the site’s company must be an ENERGY STAR partner. Earlier this year, Toyota Motor Engineering & Manufacturing North America, Inc. (TEMA) received its eighth consecutive ENERGY STAR Sustained Excellence Award for its continued leadership in protecting the environment through energy efficiency and management.

“Thanks to the efforts of our team members, Toyota has reduced our total energy use per vehicle over the last five years as we achieved greater energy efficiency across North America,” said TEMA Executive Vice President Steve St. Angelo. “This demonstrates that when good ideas are shared, great things can happen as we continuously identify new opportunities to reduce energy consumption while improving our processes.”

The eight Toyota facilities recognized by the EPA include: Bodine Aluminum (Jackson, Tenn., and St. Louis, Mo.); Toyota Motor Manufacturing, Alabama (Huntsville); Toyota Motor Manufacturing Canada (Cambridge and Woodstock, Ont.); Toyota Motor Manufacturing, Indiana (Princeton); Toyota Motor Manufacturing, Texas (San Antonio); and Toyota Motor Manufacturing, West Virginia (Buffalo).

Several examples of reduction in energy intensity include:

 

Plant Kaizen (Improvement) Example	Description	Benefits	Industry Challenge Energy Reduction (From Baseline)
Lighting efficiency (Bodine Aluminum, Jackson, Tenn.)	Replacement of lighting in several plant areas with energy efficient florescent lights with sensors	• Reduce CO2 emissions • Cost savings • Reduce energy usage	13.8%
Innovative lighting technology (Toyota Motor Mfg., Alabama)	Installation of Ultra Constant Discharge lighting in the plant’s parking lot	• Reduce CO2 emissions • Cost savings • Reduce energy usage	24.1%
Hot water boiler linkage (Toyota Motor Mfg. Canada)	Installation of new controls allowing proper mixture without numerous adjustments	• Reduce CO2 emissions • Reduce water usage	28.5%
		• Reduce energy usage • Less complexity
Paint booth HVAC system (Toyota Motor Mfg., Indiana)	Elimination of using outside air to cool/heat paint booth; current air intake is taken directly from plant, making temperature consistent	• Reduce CO2 emissions • Reduce energy usage • Less use of HVAC system, natural gas and electricity during peak times	36%

Since 2006, Toyota’s U.S. manufacturing operations have received 18 Energy Star Plant Awards from the U.S. EPA, recognizing each plant’s energy performance over the past year and scoring in the top 25 percent of its industry.