A collection of case studies
for such as recycle design that
contribute towards improving
the ease of dismantling
end-of-life vehicles

March 2021
Japan ELV Recycler’s Association

This document was created by the Japan ELV Recycler’s Association(JAERA) with assistance from the Japan Foundation for Advanced
Auto Recycling (J-FAR). Do not quote or reprint any part of thispublication without permission from JAERA.
Japan ELV Recycler’s Association
5th Floor Ravina Shibashi, 3-2-2 Shinbashi, Minato-ku, Tokyo 105-0004
http://elv.or.jp/

Introduction
Automobile recycle business operators have been making progress with efficientdismantling and the proper disposal of automobiles in accordance with the Act
on Recycling, etc. of End-of-Life Vehicles (hereafter, Automobile Recycling Law)
enacted from January 2005. However, public opinion for the effective use ofresources has increased even more such that it is necessary to accelerate initiatives
with the aim of further promoting the reuse of resources and the advancementof recycling. Under these circumstances, automobile manufacturers have been
aiming for the advancement of automobile recycling and have been working
towards a recycle design that takes into consideration the ease of dismantling
automobiles from around the year 2000. It is speculated that the number of endof life vehicles (ELV) influenced by these initiatives has increased in recent years.
When dismantling operators are extensively aware of and use this type of recycle
design, which automobile manufacturers are working on, it is believed that it willlead to the effective use of resources.
In contrast, the Industrial Structure Council Industrial Technology and Environment
Subcommittee Waste and Recycling Subcommittee Automobile Recycling WG/
Central Environment Council Recycling Society Subcommittee Automobile Recycling
Special Committee Joint Meeting collated a “Report for the Assessment andExamination on the Enforcement of the Automobile Recycling System” at the 10th
anniversary following the enactment of the Automobile Recycling Law. This reportconsidered “3R promotion and quality improvement for automobiles” as one of
the fundamental directions, and included the “Promotion of environment-friendly
design and its use” as a specific initiative. This report shows that it is necessary
for dismantling operators and automobile manufacturers and similar enterprises
to cooperate and move forward with the efficient introduction of environmentfriendly design (otherwise known as Design for Environment or DfE) and share
their information, and then continuously conduct follow-up for these activities.
Furthermore, in a report compiled by the “Investigation committee for the 3R
promotion and quality improvement for automobile recycling” established after
receiving the joint council report, it clearly states cooperative-based promotion
between automobile manufacturers and dismantling operators, and includes thepromotion of effective DfE introduction based on (1) raising awareness of DfE
information with dismantling operators and promoting efficient dismantling bysuch operators, and (2) actual work conditions by providing feedback of opinionsfrom the dismantling process to the design process.
Under these circumstances, with the assistance of J-FAR and the aim of building
a common understanding for recycle design between dismantling operators andautomobile manufacturers, JAERA has now decided to create a collection ofrecycle design case studies organized into good examples of recycle design anddismantling that can be easily used by dismantling operators. This document is
a collection of recycle design information achieved with the cooperation of theJapan Automobile Manufacturers Association (JAMA) and provides information
based on our investigation of recycle design awareness and good examples
after conducting interviews and extensive questionnaires with many dismantlingoperators. We would like to take this opportunity to thank everyone who helped
create this document, and hope that it will further stimulate communication
between dismantling operators and automobile manufacturers.
Japan ELV Recycler’s Association
1

Contents

1. Overview
1.1. About this project .............................................................. 6
1.2. Structure of this document ................................................. 7
2. Recycle design by automobile manufacturers
2.1. Awareness and effectiveness of recycle design ...................... 8
2.2. Improvement requests for automobile design ...................... 11
2.3. Examples of improvement requests(1) Add engine hooks .......................................................... 12(2) Standardize the engine computer installation position ......... 12(3) Improve of valve positions on the air conditioning pipes ...... 13(4) Standardize caution plate installation positions................... 13
3. Examples of recycle design by automobile manufacturers
3.1. Providing information for dismantling methods(1) Providing information relating to secondary dismantlingjigs & tools ................................................................... 15(2) Providing information relating to dismantling jigs & tools ..... 16(3) Providing information for dismantling methods .................. 172

Contents

3.2. Improving visibility for when separating parts from vehicles(1) Displaying material properties in multiple locations
on long resin parts ......................................................... 20(2) Displaying material properties that can be verified
in an assembled state .................................................... 21(3) Displaying positions where parts are easy to detach(marks for improved dismantling) .................................... 22(4) Displaying locations where parts are easy to detach(finger hook positions) ................................................... 23(5) Displaying locations where parts are easy to detach(tape for improved dismantling) ...................................... 24(6) Clearly indicating locations to drain liquids ........................ 25(7) Setting labels for mounting positions ................................ 26
3.3. Improving the structure to reduce the work
(1) Ability to directly remove the tank alone ........................... 27(2) Improving access to batch operation connectors ................ 28
3.4. Improving installation positions(1) Setting wiring routes that consider detachment ................. 29(2) Arranging high and low valves in close proximity ................ 30
3.5. Changing fastening structures(1) Improving the ease at which parts can be detached(such as reducing the thickness of fastening areas) ............ 31(2) Improving the ease at which parts can be detached(improving the structure of fastening areas) ...................... 32(3) Ability to remove without tools ........................................ 33(4) Changing to fastening with clips ....................................... 34(5) Setting securing bolt shapes that match the hub nut size .... 35(6) Changing to fastening with fitting structures andclips, etc. ...................................................................... 36

3

Contents

3.6. Other considerations(1) Ability to directly remove the rear bumper ........................ 37(2) Setting flat surface areas for leak prevention ..................... 38
4. Good examples of dismantling operators
4.1. Using a chassis number stamping list
(optimizes chassis number verification) .............................. 41
4.2. Free lending of air bag batch operation tool ......................... 41
4.3. Setting a drop-prevention bar when draining liquids ............. 42
4.4. Removing the fuel tank pump ........................................... 43
4.5. Creating a procedure panel for HV battery removal .............. 44
4.6. Making a pre-processing manual to improve thevolume of retrieved wire harnesses .................................... 44
4.7. Retrieving parts attached to harnesses using thefeet of heavy dismantling machinery .................................. 45
4.8. Developing recycled goods and art from automobile parts ..... 46

4

MEMO

5

1. Overview

1.1. About this projectThis document was created as part of a grant project from the Japan Foundation for
Advanced Auto Recycling (J-FAR). The aim of this project was to disseminate recycle
design for automobiles and it included the investigation and sorting of recycle design
examples for automobile manufacturers, questionnaire surveys concerning dismantlingoperator awareness and effectiveness of recycle design, and interviews with dismantlingoperators about recycle design. This document was then created based on these tasks.
We have selected items that companies need to be particularly very aware of fromamong initiatives concerning recycle design at automobile manufacturers, and haveintroduced these using diagrams and photos in this document. Furthermore, we haveprovided an overall picture of initiatives at automobile manufacturers on pages 8-9 where
it was not possible to introduce the specifics of these initiatives so please refer to thispage along with the rest of the document.
In addition to continuing our discussions with JAMA, which continues to be a partner,concerning issues relating to design and such matters identified during questionnaires
and interviews with dismantling operators, we have also introduced good examples
from dismantling operators on page 40 and onwards for examples in which individual
dismantling operators have resolved some issues by means of their own initiative.
We hope that recycle design by automobile manufacturers and these initiatives fromindividual dismantling operators will be of use and lead to an improvement in dismantlingefficiency.
Details of this project are scheduled to be published on the J-FAR website around June
2021 as a project report.
* Japan Foundation for Advanced Auto Recycling (J-FAR) website
https://j-far.or.jp/<Investigation conducted for this project>
Content

Overview

Questionnaire
Survey[Survey period] Questionnaires collected during September 7, 2020 - December
4, 2020[Survey method] Mail survey (responses were requested by telephone after
sending)[Number of companies targeted] 3,476 operators registered in the automobile
recycling system[Number of companies who responded] 447 (collection rate of 12.9%)[Survey content](1) Awareness of recycle design design of automobile manufacturers(2) Effectiveness of recycle design of automobile manufacturers(3) Improvement requests for such as design that leads to improvements in easeof dismantling

Interviews[Survey period] September 10, 2020 - November 16, 2020 (total of 9 times)[Survey method] Group interviews using web conferencing[Number of companies targeted] Total of 84 people from 71 companies who are
Japan ELV Recycler’s Association members[Question content](1) Opinions on recycle design of automobile manufacturers(2) Improvement requests for such as design that leads to improvements in easeof dismantling(3) Initiatives from dismantling operators that leads to improvements in ease of
dismantling61. Overview

1.2. Structure of this document
An outline of the questionnaire for dismantling operators conducted during this project
can be found in section “2. Recycle design by automobile manufacturers” (pages 8 to
13). This section lists improvement requests concerning such as automobile design,
and recycle design awareness and effectiveness as provided in the responses from all
dismantling operators.
Furthermore, section “3. Examples of recycle design by automobile manufacturers”(pages 14 to 38) lists items that companies need to be highly aware of in particular fromamong the recycle design examples collected during this project. Each example has beenorganized by the automobile manufacturer’s initiative content with such factors as thetarget work, corresponding manufacturer, initiative point, and images of initiative content.
Section “4. Good examples of dismantling operators” (pages 40 to 47) introduces
examples where initiatives from individual operators resolved issues relating to suchthings as design for which we received opinions about during the questionnaire andinterviews stage. Therefore, we hope you will take a look at this information. We would
also like to take this opportunity to thank those operators who provided this information.
<How to read the recycle design examples>[Initiative content]

3. Automobile manufacturer recycle design examples

Shows the automobile
manufacturer’s initiative.

(2)

Target work

[Target work]

Removing resin parts

Shows the work process thatmakes the best use of thisinitiative.
[Corresponding manufacturer]*<Keypoint>
Enable resin material you want toretrieve to be retrieved without wasting

Shows the automobile
manufacturer that verified thisinitiative.

resin part material properties can be[Initiative key points][Display position for material properties]

Shows an outline of this initiative
using explanations and conceptual
drawings.

• Subaru
Front bumper[Initiative details]• Toyota (Engine under cover)Shows details for this initiative
using photos and conceptual
drawings.

Engine under cover* The “Corresponding manufacturer” section
covers a range of manufacturers identified
while conducting investigations for thisproject, and may not necessarily be limited
to these manufacturers.

21

7

2. Automobile manufacturer recycle design

2.1. Awareness and effectiveness of recycle design
The table below shows recycle design targeted by this project.
We investigated the “awareness” and “effectiveness” of each of these initiatives aspart of this study.
<Recycle design targeted by this project>
No.

Initiative content

Target parts

1

Providing information by meansof a service manual

Power control unit, wire
harness, fuel tank, etc.

2

Providing information relating tosecondary dismantling jigs

Various computers

3

Providing information relating
to dismantling jigs & tools

Various compact motors

4

Providing information for dismantling methods

Traction battery/power storage system

5

Material properties markings based on ISO

Resin parts of 100 g or more,
Rubber parts of 200 g or more

6

Displaying material properties in
multiple locations on long resin parts

Bumper, instrument panel

7

Displaying material properties that canbe verified in an assembled stateEngine under cover

8

Displaying positions where parts are easy todetach (Marks for improved dismantling)

Bumper, instrument panel, trims, fueltank, air bag, traction battery, etc.

9

Displaying positions where parts are easy
to detach (Tape for improved dismantling)

Wire harness

10

Clearly indicating locations to drain liquids

Waste oil and waste liquids

11

Setting labels for mounting positions

Lead-acid battery/traction battery/power
storage system (HV, PHV and FCV only)

12

Improving visibility for installation areas

Fuel tank13

Improving visibility for fastening areas

Heater unit, meter, radar,
instrument panel, air bag

14

Improving visibility for extraction ports/valves

Fluorocarbon

15

Improving separability of plating parts

Bumper16

Ability to retrieve just the motor unit

Various compact motors

17

Ability to directly remove the tank alone

Fuel tank18

Improving the ease at whichparts can be detached(such as the addition of slits)

Carpet19

Displaying positions where parts areeasy to detach (finger hook positions)

Door trims

20

Prohibiting fastening from thetransverse direction (improving
workability when tires are present)

Engine under cover

21

Using pads with no insertion

Front seat

22

Improving access to batch
operation connectors

Air bag

23

Setting flat surface areas for leak prevention

Fuel tank24

Secure demolition space

Various computers, heater unit, meter, air bag

8

2. Automobile manufacturer recycle design<Investigation conducted for this project>
No.

Initiative content

Target parts

25

Maintaining extraction space

Fluorocarbon, waste oil and waste liquids

26

Setting the fastening areas at a position thatis easy to see and access

Various compact motors

27

Setting wiring routes that consider detachment

Wire harness

28

Arranging Hi/Lo valves in close proximity

Fluorocarbon

29

Reducing the number of fastening points

Various interior parts, air bag, lead-acidbattery, etc.

30

Improving the ease at which parts can be
detached (such as reducing the thickness offastening areas)

Bumper, instrument panel

31

Improving the ease at which parts can be
detached (improving the structure of fastening
areas)

Wire harness

32

Ability to remove without tools

Weather stripping, door glass run

33

Changing to fastening with clips

Bumper, back door

34

Prohibiting such as metal inserts andembedded bolts

Bumper, edge protection

35

Regulating the types of bolts and securing
clips, etc.

Fender liner, Radiator grill, under cover,various trims, etc.

36

Setting securing bolt shapes that match the
hub nut size

Spare tire

37

Avoiding bonded component parts and rivet
fastened structures

Radiator grill38

Not using adhesive when attaching such as
different materials

Instrument panel, door trims, other trims,
instrument cluster

39

Changing to fastening with fitting structuresand clips, etc.

Cowl louver, door trims, center cluster

40

Standardize materials (change to single
material)

Bumper, interior parts

41

Using general-purpose material for aluminum
wheels used by other companies

Tires, wheels

42

Sealant and insulation material with samematerial properties as main body

Heater duct

43

Improving ability to drain liquids

Engine, power control unit

44

Regulating the volume and time for draining
liquids

Waste oil and waste liquids

45

Ability to directly remove the rear bumper

Bumper46

Structures that can be disassembled on theinsideHeadlights

47

Binding with tubes and tape to prevent parts
from unraveling or coming apart

Wire harness

48

Reducing the number of component parts(such as welding the defroster duct)

Instrument panel

49

No edges or burrs on the bottom of the seat

Front seat

50

Setting a notch in the frame unit pad for theframe integrated foam pad

Rear seat51

Setting a position to grip for dismantling

Rear seat92. Automobile manufacturer recycle design
The investigation results clearly showed that dismantling operators are not always
aware of automobile manufacturer recycle design. Out of the 51 initiatives that were
investigated, no initiatives were below 10% for awareness, but 41 initiatives were under
50% for awareness, which was the majority of the initiatives.
Meanwhile, for the effectiveness, 47 initiatives were evaluated to be more than
50% as effective initiatives by operators (or seemed to be effective initiatives), and it
was considered highly likely that this contributed to efficient dismantling even thoughawareness was low.
In particular, efforts to dismantle and dispose of parts that many businesses are required
to dismantle and dispose of, such as fluorocarbon, air bags, waste oil and liquids, storage
batteries, and wire harnesses tend to be highly evaluated.
<Awareness (Total of 51 initiatives)>
10% to below 30%
50% to below 70%<Effectiveness (Total of 51 initiatives)>
70% to below 90%
30% to below 50%

30% to below 50%
70% to below 90%

7.8%

2.0%

17.6%

50% to below 70%
10% to below 30%

19.6%
33.3%
58.9%

60.8%

* Ratio for replies that stated “I know about
this initiative”* Ratio for replies that stated “It is effective”
or “It may be effective”<Initiatives for which the reply was “It is effective” from dismantling operators (top 10 initiatives)>
No.

Initiative details

Target parts

Effectiveness1

Maintaining extraction space

Fluorocarbon, waste oil andwaste liquids

82.0%

2

Providing information for dismantling methods

Traction battery/power storage
system81.0%

3

Improving visibility for extraction ports/valves

Fluorocarbon

79.9%

4

Improving the ease at which parts can be detached(improving the structure of fastening areas)

Wire harness

79.2%

5

Arranging Hi/Lo valves in close proximity

Fluorocarbon

77.9%

6

Improving access to batch operation connectors

Air bag

77.6%

7

Setting wiring routes that consider detachment

Wire harness

77.5%

8

Setting labels for mounting positions

Lead-acid battery/traction
battery/power storage system

76.4%

9

Improving the ease at which parts can be detached(such as reducing the thickness of fastening areas)

Bumper, instrument panel

75.7%

10

Ability to directly remove the rear bumper

Bumper74.8%

10

2. Automobile manufacturer recycle design

2.2. Improvement requests for automobile design
There were many requests as shown mostly in the table below during the questionnaire.
Similar requests were identified during interviews with dismantling operators so we believethat many dismantling operators have a shared awareness of the problems they face.
We intend to continue initiatives towards improving the ease of dismantling with each automobile
manufacturer through JAMA for these improvement requests from dismantling operators.
Some specific examples that are issues when dismantling are introduced on the next page.
<Improvement requests from dismantling operators>
Target parts

Improvement requests
Improve visibility of raw material information (enlarge the display, clarify and fix displayed positions, etc.)

BumperDesign to ensure minimal damage during removal (break-off prevention, etc.)
Strengthen installation and fitting areas

Bonnet hood
Headlights
FenderBack door
Tires, wheels

Clarify material properties information for such as iron and aluminum
Reduce uneven surfaces (improve safety)
Improve visibility of raw material information (enlarge the display, clarify and fix displayed positions, etc.)
Improve separability of harnesses
Clarify material properties information for such as iron and aluminum
Improve separability of harnesses and motors
Clarify material properties information for such as iron, aluminum and resinsStandardize screws and wheel nuts
Add engine hooks

EngineImprove separability of harnesses
Improve separability of mounts

Catalyst

Variouscomputers
Variouscompact motors
Wire harness
Instrument
panel
Door trims
Fluorocarbon

Display at positions where numbers are highly visible
Set up as single parts (separate from pipes)
Standardize installation positionsShow part name on exterior
Improve separability from electronic board
Improve access
Provide measures for aluminum harnesses (make it easy to identify)
Improve visibility for cover tube and tape colors
Improve visibility of raw material information (enlarge the display, clarify and fix displayed positions, etc.)
Improve separability of harnesses
Improve visibility of raw material information (enlarge the display, clarify and fix displayed positions, etc.)
Improve separability of harnesses when using heavy dismantling machinery
Improve valve positions (easy to know positions)Improve access to air bag computer

Air bagStandardize air bag computer installation position
Improve the ease at which parts can be removed

Waste oil andwaste liquids

Improve drain positions (easy to drain positions)

Tractionbattery

Devise a setup that is easy to lift (concern for dismantling using a forklift truck)

Caution plate

Standardize installation positions

Improve the ease at which parts can be removed

11

2. Automobile manufacturer recycle design

2.3. Examples of improvement requests(1) Add engine hooks
Vehicles that already have engine hooks installed on them from the start enable theengine to be transported from the vehicle more safely and efficiently when performing
this task.

(2) Standardize the engine computer installation position
When the engine computer installation position has been standardized, it can be
retrieved more efficiently.
• Installation position; Inside engine room • Installation position: Engine• Installation position; Inside dashboard (passenger seat side)

You can see that themounting position isdifferent depending on
the vehicle model...

122. Automobile manufacturer recycle design(3) Improve valve positions on the air conditioning pipes
When the high-pressure valve and low-pressure valve on the air conditioning pipes
are set close to each other, the worker can simultaneously connect a collecting machineso this allows fluorocarbon to be collected efficiently.

Valve positions are
separate from eachother so it is difficult toperform the task...

(4) Standardize caution plate installation positions
When caution plate installation positions have been standardized, this improves efficiency
when identifying the vehicle model.
Installation position: Radiator support

Installation position: Dash panel

Installation position: Center pillar

13

3. Automobile manufacturer recycle design examples
This section includes the following recycle design examples.
No.

Initiative details

Target parts

3.1.(1)

Providing information relating to secondary
dismantling jigs & tools

Various computers3.1.(2)

Providing information relating to dismantlingjigs & tools

Various compact motors

3.1.(3)

Providing information for dismantling
methods

Traction battery/power storage
system

3.2.(1)

Displaying material properties in multiple
locations on long resin parts

Bumper, instrument panel

3.2.(2)

Displaying material properties that can beverified in an assembled state

Bumper, engine under cover3.2.(3)

Setting positions where parts are easy todetach (Marks for improved dismantling)

Bumper, instrument panel

3.2.(4)

Setting positions where parts are easy todetach (finger hook positions)

Door trims

3.2.(5)

Setting positions where parts are easy todetach (Tape for improved dismantling)

Wire harness

3.2.(6) Clearly indicating locations to drain liquids

Waste oil and waste liquids

3.2.(7) Setting labels for mounting positions

Lead-acid battery/traction battery/
power storage system

3.3.(1) Ability to directly remove the tank alone

Fuel tank

3.3.(2)

Improving access to batch operation
connectors

Air bag3.4.(1)

Setting wiring routes that consider
detachment

Wire harness

3.4.(2) Arranging Hi/Lo valves in close proximity

Fluorocarbon

Improving the ease at which parts can be
3.5.(1) detached (such as reducing the thickness offastening areas)

Bumper, instrument panel

Improving the ease at which parts can
3.5.(2) be detached (improving the structure offastening areas)

Wire harness

3.5.(3) Ability to remove without tools

Weather stripping, door glass run

3.5.(4) Changing to fastening with clips

Bumper, back door

3.5.(5)

Setting securing bolt shapes that match the
hub nut size

Spare tire

3.5.(6)

Changing to fastening with fitting structuresand clips, etc.

Cowl louver, door trims, center cluster

3.6.(1) Ability to directly remove the rear bumper

Bumper

3.6.(2) Setting flat surface areas for leak prevention

Fuel tank14

3. Automobile manufacturer recycle design examples

3.1. Providing information for dismantling methods(1) Providing information relating to secondary dismantling jigs & tools
Target work

Removing the computer electronic board<Keypoint>
Devise a jig that presses onto and cuts
the bonded resin case using a single
action so that the electronic board canbe retrieved efficiently.

[Computer dismantling jig]
You can see that it
makes it easy toremove only the
motor unit!

[Computer dismantling work]15

3. Automobile manufacturer recycle design examples(2) Providing information relating to dismantling jigs & tools

Target work

Removing compact motors<Keypoint>
Devise a dismantling jig that simply
twists the motor unit from the wiper
motor ASSY so that the copper wire coilcan be retrieved efficiently.

[Compact motor dismantling jig]
You can see that it
makes the work ofseparating material
easier!

[Compact motor dismantling work]16

3. Automobile manufacturer recycle design examples(3) Providing information for dismantling methods

Target work

Removing the traction battery<Keypoint>
Issue a manual to retrieve thesecondary traction battery so that it canbe removed safely and reliably.

[Retrieval manual]
HV battery removal procedures

HV battery storage method

HV battery retrieval method17

3. Automobile manufacturer recycle design examples
You can find detailed information at the URLs shown below for recycling traction
batteries that require proper disposal from automobile manufacturers.

* Information is current as ofthe end of February 2021

<Recycle information for traction batteries>

Manufacturer

URL

Suzukihttps://www.suzuki.co.jp/about/csr/recycle/traders/

Subaruhttps://www.subaru.co.jp/products/recycle-lithium.html

Daihatsu

https://www.daihatsu.com/jp/csr/environment/recycle/hvrecycle.html

Toyotahttps://global.toyota/jp/sustainability/esg/challenge2050/
challenge5/proper-disposal/

Nissanhttps://www.nissan-global.com/JP/ENVIRONMENT/A_
RECYCLE/BATTERY/

Honda

https://www.honda.co.jp/auto-recycle/recycle_07.html

Mazda

https://www.mazda.com/ja/csr/recycle/lithium/

Mitsubishi

https://www.mitsubishi-motors.com/jp/sustainability/
environment/recyclelow/battery.html

Hino

https://www.hino.co.jp/ts/after_service/hv_battery_recycle/<Reference> You can also use the following web page to check the manufacturer URLs.
JARP website http://www.jarp.org/duties/lib/

18

3. Automobile manufacturer recycle design examples
We also provide a rescue manual as reference information to perform dismantling worksafely on vehicles that were involved in an accident.
You can find rescue manuals from automobile manufacturers at the URLs shown below.

* Information is current as ofthe end of February 2021

<Rescue manual information>

Manufacturer

URL

Suzukihttps://www.suzuki.co.jp/car/afterservice/rescuemanual/

Subaruhttps://www.subaru.co.jp/products/rescue-hybrid.html

Toyotahttps://global.toyota/jp/your-vehicle/quick-referencesheet/Nissanhttps://www.nissan-global.com/JP/SAFETY/RESCUE/

Honda

https://www.honda.co.jp/rescue-auto/

Mazda

https://www.mazda.co.jp/carlife/owner/advice/rescue/

Mitsubishi

https://www.mitsubishi-motors.co.jp/support/rescue/

Hino

https://www.hino.co.jp/ts/after_service/hv_resucue/

19

3. Automobile manufacturer recycle design examples
3.2. Improving visibility for when separating parts fromvehicles(1) Displaying material properties in multiple locations on long resin parts
Target work

Removing resin parts<Keypoint>
Set material properties indicators sothat the material properties of retrieved
resin parts can be easily verified bydisplaying such indicators at regularintervals on the flat surface of the part.

[Display position for material properties]• Rear bumper

20

3. Automobile manufacturer recycle design examples(2) Displaying material properties that can be verified in an assembled state

Target work

Removing resin parts<Keypoint>
Enable resin material you want toretrieve to be retrieved without wastingtime and effort by ensuring that theresin part material properties can beverified before dismantling.

[Display position for material properties]• Subaru
Front bumper• Toyota (Engine under cover)Engine under cover21

3. Automobile manufacturer recycle design examples(3) Displaying positions where parts are easy to detach (marks for
improved dismantling)

Target work

Removing bumpers<Keypoint>
Set marks for improved dismantling toindicate the position where parts can beeasily retrieved by detaching them orsimilar action.

[Display position for material properties]• Front bumper

It has easy to seemarks!

22

3. Automobile manufacturer recycle design examples(4) Displaying positions where parts are easy to detach (finger hookpositions)Target work

Detaching door trims<Keypoint>
Clearly indicate locations where there
is sufficient space for fingers to enter
to start detaching door trims when
performing this task.

[Display finger hook positions][When performing work to detach parts]23

3. Automobile manufacturer recycle design examples(5) Displaying positions where parts are easy to detach (tape for improved
dismantling)

Target work

Detaching wire harnesses<Keypoint>
Set green tape on points where it is theeasiest to retrieve wire harnesses.

[Tape position]• Instrument panel wire

[When performing work to detach parts]<Hold the section where tape is affixed> <Detach while maintain the hold on the part>24

3. Automobile manufacturer recycle design examples(6) Clearly indicating locations to drain liquids

Target work

Extracting fuel<Keypoint>
Clearly indicate the lowest position
that will not interfere with the built-in
elements of the fuel tank as the position
to drill a hole when extracting the fuel.

[Display position for location to drain liquids]• Mazda• Toyota25

3. Automobile manufacturer recycle design examples(7) Setting labels for mounting positions

Target work

Removing traction battery and power storage system parts<Keypoint>
Set and display mounting position labels
on vehicles so that it is easy to see themounting position of traction battery
and power storage system parts at thework site[Display position for mounting position labels]This makes it easy
to know where themounting locations
are.

26

3. Automobile manufacturer recycle design examples

3.3. Improving the structure to reduce the work
(1) Ability to directly remove the tank alone
Target work

Removing the fuel tank

<Keypoint>
Improve the placement of peripheral
parts so that the fuel tank can bedirectly removed with the goal of
improving work efficiency.

[Installed state][When removing]27

3. Automobile manufacturer recycle design examples(2) Improving access to batch operation connectors

Target work

Air bag batch operation processing<Keypoint>
Improve the design to enable easy
access to the airbag computer by
installing a service hole cover, etc.

[Mounting positions for batch operation connectors]• Service hole cover• Batch operation connector

It’s so much easier
to deploy the air bagwith this method!

28

3. Automobile manufacturer recycle design examples

3.4. Improving installation positions(1) Setting wiring routes that consider detachment
Target work

Detaching wire harnesses<Keypoint>
Improve the harness route so that thewire harness is easy to grab and does
not interfere with other parts when
detaching it using heavy dismantlingmachinery.

[Wire harness routing]• Toyota• Nissan• Mitsubishi
You can see it wasdevised to notinterfere with otherparts.

29

3. Automobile manufacturer recycle design examples(2) Arranging Hi/Lo valves in close proximity

Target work

Collecting fluorocarbon gas<Keypoint>
The high pressure side and low pressure
side valves on the refrigerant piping arelocated inside the engine compartment,
allowing the worker to connect therefrigerant recovery device without
moving.

[Fastening bolts installed state]• Nissan• Mazda• Toyota• Honda30

3. Automobile manufacturer recycle design examples

3.5. Changing fastening structures(1) Improving the ease at which parts can be detached (such as reducing
the thickness of fastening areas)
Target work

Detaching bumpers<Keypoint>
Improve the structure to allow foreasy detachment when pulling in the
detachment direction because thebumper fastening area has a thinnersection and a slit.

[Front bumper fastening area]
Thinner section

Slit
This structure
makes it easierto remove whenrecycling.

31

3. Automobile manufacturer recycle design examples(2) Improving the ease at which parts can be detached (improving thestructure of fastening areas)

Target work

Detaching wire harnesses (grounding terminal)<Keypoint>
Improve the structure to allow foreasy detachment when pulling in
the detachment direction because
the grounding terminal has a thinnersection.

[Detaching the wire harness]

It has a pull tab
similar to opening a
can of soda!

32

3. Automobile manufacturer recycle design examples(3) Ability to remove without tools

Target work

Removing weather stripping and door glass run<Keypoint>
Enable these parts to be removed easily
without using tools when performing
this task.

[Weather stripping][Door glass run]33

3. Automobile manufacturer recycle design examples(4) Changing to fastening with clips

Target work

Removing bumpers<Keypoint>
Enable this part to be removed easily
even when using heavy dismantlingmachinery by changing to fittings thatuse hooks and clips instead of bolts
and screws that were used at fastening
areas.

[Front bumper installed state]This structure makes
it easier to remove
when recycling.

34

3. Automobile manufacturer recycle design examples(5) Setting securing bolt shapes that match the hub nut size

Target work

Removing the spare tire

<A is the same size as the hub nut>
<Keypoint>
Enable installation/removal using power
tools by setting a bolt shape with thesame size as the hub nut at the top of
the spare tire securing bolt.

[Conventional part][Recycle designed part]35

3. Automobile manufacturer recycle design examples(6) Changing to fastening with fitting structures and clips, etc.

Target work

Removing the center cluster panel, etc.

<Keypoint>
Enable this part to be removed easily
by changing screw fastenings that uses
bolts and screws to a fitting structurethat uses clips.

[Installed state]It’s now possible toremove it without
using tools.

[Removed state]36

3. Automobile manufacturer recycle design examples

3.6. Other considerations(1) Ability to directly remove the rear bumper
Target work

Detaching rear bumpers<Keypoint>
Enable the rear bumper to be removed
without needing to remove other parts
such as the rear combination lamp.

[Installed state]
You can see it wasdevised so that justthe bumper can beremoved.

[Removed state]37

3. Automobile manufacturer recycle design examples(2) Setting flat surface areas for leak prevention

Target work

Extracting fuel<Keypoint>
Set a flat surface to enable a hole tobe drilled easily by the fuel extraction
device drill or to maintain the sealing
properties with the boots.

[Indicator showing flat surface for fuel tank]It’s a flat surface so fuel can becollected without it leaking while
the boots are in close contact!

38

MEMO

39

4. Good examples of dismantling operators
Personal initiatives from dismantling operators can also achieve improvements in both
efficiency and safety of automobile dismantling, not just recycle design from automobile
manufacturers. This section introduces some initiatives from all dismantling operators
in response to issues that were revealed during the investigation conducted as part ofthis project.

No.

Operator who provided
the information

Overview of good examples

1

Tochigi Parts Co., Ltd.

Using a chassis number stamping list

2

Okinawa Car Recycling CoopFree lending of air bag batch operation tool3

eco-R Co, Ltd.

4

Carec Co., Ltd.

5

Auto Parts Izichi Co., Ltd.

6

Carglee Comazen Co., Ltd.

7

Towa Co., Ltd.

Setting a drop-prevention bar when draining
liquids
Removing the fuel tank pump
Creating a procedure panel for HV battery
removalMaking a pre-processing manual to improve theamount of retrieved wire harnesses
Retrieving parts attached to harnesses using thefeet of heavy dismantling machinery

Takunan Metal Trade Co., Ltd.
8

Matec Corporation

Developing goods and art from automobile parts

Kaiho Industry Co., Ltd.

40

4. Good examples of dismantling operators
4.1. Using a chassis number stamping list
(optimizes chassis number verification)
Issue

Verifying caution plate installation positions<Good example>
Tochigi Parts Co., Ltd. uses the stamping position of the chassis number published on
the Internet to achieve optimization of chassis number verification work.

Source: Kurunavi website https://www.kurunavi.jp/index.html

4.2. Free lending of air bag batch operation tool
Issue

Popularizing the use of the air bag batch operation tool

<Good example>
Okinawa Car Recycling Coop has purchased a batch operation tool for their cooperativeand lends this tool to its members and provides assistance to purchase the tool,
including ISO methods that have not become mainstream.
[Batch operation tool method]<JAMA method><ISO method>41

4. Good examples of dismantling operators

4.3. Setting a drop-prevention bar when draining liquids
Issue

Risk of the vehicle falling down when draining liquids using a thrustcutter<Good example>
eco-R Co, Ltd. Has set a drop-prevention bar to prevent the vehicle from falling downwhen the tip of the thrust cutter pierces the fuel tank.
[Drop-prevention bar]
<Drop-prevention bar not being used><Drop-prevention bar in use>

It's surprising how much the forceof the thrust cutter moves thevehicle body when the tip pierces
the fuel tank!!

42

4. Good examples of dismantling operators

4.4. Removing the fuel tank pump
Issue

Removing the fuel pump from older model year vehicles<Good example>
Carec Co., Ltd. Has devised a unique jig that they use when removing the fuel pumpwith the goal of improving safety and efficiency.
[Fuel pump removal jig]
Section that connects to retainer<Before removing the pump retainer><After removing the pump retainer>

It looks like this jig can makeremoving the fuel pump easy!

43

4. Good examples of dismantling operators

4.5. Creating a procedure panel for HV battery removal
Issue

Checking the method for removing the traction battery<Good example>
Auto Parts Izichi Co., Ltd. displays a panel listing the traction battery removal procedurein their factory with the goal of improving safety and making work instructions more
efficient.

4.6. Making a pre-processing manual to improve the amountof retrieved wire harnesses
Issue

Optimizing the retrieval of wire harnesses<Good example>
Carglee Comazen Co., Ltd. has created a manual for the pre-process stage of wire
harness retrieval and shared this within their company with the goal of optimizing theretrieval of wire harnesses using heavy dismantling machinery.
኱ᆺ䛾䝙䝤䝷䛷䝽䜲䝲䞊䝝䞊䝛䝇䜢ᅇ཰䛩䜛䛯䜑䛾๓ฎ⌮䐟䜶䞁䝆䞁䝹䞊䝮๓ฎ⌮䐠ᐊෆ䝝䞊䝛䝇๓ฎ⌮䠡/䠣䝹䞊䝮䛸ᐊෆ䛾ቃ┠䛷䚸᥋ྜ㒊䛿 䜹䝑䝖䛧䛶䛟䛰䛥䛔䚹䝙䝤䝷䛷䛾ᅇ཰䛜ᐜ᫆䛻䛺䜚䜎䛩䚹䝃䜲䝗䝣䝻䜰䛾୰䛻䛒䜛䝝䞊䝛䝇䛿䚸䝙䝤䝷䛷䛿ᅇ཰䛧䛪䜙䛔Ⅽ䝣䝻䜰䛾䝇䜹䝑䝣䝥䝺䞊䝖䜢䛿䛪䛧䝝䞊䝛䝇䜢ୖ䛻ᘬ䛝ୖ䛢䛶䛚䛔䛶䛟䛰䛥䛔䚹44

4. Good examples of dismantling operators
4.7. Retrieving parts attached to harnesses using the feet ofheavy dismantling machinery
Issue

Separating parts attached to wire harnesses<Good example>
Towa Co., Ltd. separates parts attached to wire harnesses with great efficiency using
the V-shaped section on the foot of heavy dismantling machinery.
<Heavy dismantling machinery>

V-shaped section on foot<When detaching the wire harness>

Attached parts are separated

45

4. Good examples of dismantling operators

4.8. Developing recycled goods and art from automobile parts
Issue

Adding high value to parts and resources retrieved from automobiles<Good example>
Some dismantling operators develop new products using parts and resources retrieved
from automobiles.
[Recycled products]• Takunan Metal Trade Co., Ltd.
<Glass><Tumblers><Seat belts><Tote bags>

46

4. Good examples of dismantling operators• Matec Corporation<Air bags><Teddy bears><Leather seat covering>• Kaiho Industry Co., Ltd.
<Seats><Treasure chairs>

47

Conclusion
We consider this document to be something new for two main reasons.
The first is that it is our initial attempt to systematically collate together
examples of environment-friendly design from each automobile manufacturer
as well as information about easy dismantling techniques as seen from the levelat the dismantling operator’s workplace. From the perspective of promoting the
3Rs to create a Recycling-based Society, automobile manufacturers have beenworking hard to design products that consider the ability to recycle them fromaround the year 2000. However, the questionnaire used during our investigations
clearly shows that this information has not been communicated well. Conversely,
information such as the good and bad aspects of workability felt by dismantlingoperators as they work to dismantle vehicles was not systematically reported toautomobile manufacturers. In this sense, we believe it is very significant thatthe initiatives shown in this document have shown the direction to resolve these
problems.
The second is that we have created a stepping stone to a shared information
platform through the work, in terms of summarizing information in this documentby having dismantling operators (JAERA) cooperate with automobile manufacturers(JAMA). It is necessary to have parties concerned with manufacturing, selling,using, and recycling automobiles in the loop to create a recycling-orientatedsociety. Among these, it is believed that achieving cooperation between bothparties involved in manufacturing and recycling in particular is the key to success.
Nonetheless, the Japanese economy has grown with a linear structure in terms ofmass production, mass consumption, and mass disposal in its history so changing
this situation is not as easy as it sounds.
This document was created with the full cooperation of automobile manufacturers,
that is to say, it was completed through a collaborative process. It is the resultof specific cooperation between manufacturers and recyclers and we have highexpectations for its further development in the near future.

Japan ELV Recycler’s Association
Yasuo Sakai, Representative Director

48

A collection of case studies for such as recycle design that
contribute towards improving the ease of dismantling end-of-life vehicles

Japan ELV Recycler’s Association
5th Floor Ravina Shinbashi, 3-2-2 Shinbashi, Minato-ku, Tokyo 105-0004
http://elv.or.jp/
March 2021
(March of Japanese year 3 of Reiwa)