Toyoda Gosei Report 2009

About Toyoda Gosei Report 2009

About this Report

This report is designed to help all Toyoda Gosei’s stake-holders gain a deeper
understanding of and build further trust towards the business activities of Toyoda Gosei
Group. Therefore, we changed the report name into "Toyoda Gosei Report" to report on
the activities in wider scope, the "Social and Environmental Report" and the "Annual
Report" have been combined into one report in 2009.
This report is compiled a special future of "manufacturing" and "human resource
development" of great signiﬁcance to our company; these activities have been classiﬁed
into ﬁve categories: Operations, Management, Society, Environment, and Finance.
Environmental data can also be found on the Toyoda Gosei Home page.

The report covers theperiod between

April 1,2008 ~ March 31, 2009
*The above period forms the basis, but if necessary content related to other times outside
this period will be included.

Scope

As a general rule, the target companies are those consolidated in the Toyoda Gosei
Group.
Some of the items are mentioned individually.

Declaration of thecompany nameIn this report, Toyoda Gosei Co., Ltd. will be referred to as either "our company" or"Toyoda Gosei"; when referring to the Toyoda Gosei Group in its entirety, "Toyoda Gosei
Group" will be used.

Notices pertaining tofuture forecasts

Included in this report are predictions and forecasts pertaining to the future plans,
strategies, and achievements of Toyoda Gosei. These are predictions based not on pastfacts but on suppositions and opinions drawn from judgments made from informationthat is available to our company at this point in time. It also covers risks and uncertainty
related to such things as economic trends, intensiﬁcation of automotive industry
competition, market demand, taxation, laws, systemic changes, and natural disasters.
Please understand that it is possible that actual achievements may diﬀer from ourcompany's predictions.

Reference Guidelines"Environmental Reporting Guidelines (2007 Version)" (Ministry of the Environment)

Date of issue

July 2009 (The next publication is planned for summer, 2010)

Contact information
for comments about
this report

General Administration Division, General & Public Aﬀairs Dept. (Headquarters)
TEL. +81-52-400-1055 FAX. +81-52-409-7491
Plant & Environment Engineering Division, Environment Administration Dept
(Kitajima Technical Center)
TEL. +81-587-34-3291 FAX. +81-587-34-3309
It is possible to access this report on the Toyoda Gosei Homepage.
http://www.toyoda-gosei.com/

1

Contents

12
35About Toyoda Gosei Report 2009
Contents
Message from the President
Special Feature Supporting a technology based enterprise

23"Manufacturing" and"Human resource development"

Business Report
711

Report by Business Unit·Interior and Exterior Parts Business Unit/Body Sealing Business Unit
·Functional Parts Business Unit/Safety Systems Business Unit
·Optoelectronic Business Unit/General Industry Products Business Unit

Report by Region
·Japan/North America/Asia and Oceania/Europe and Africa

Management Report
12
13
14

15

Corporate Governance·Achieving Prompt, Efficient and Sound Business Management
·Implementation of auditing in functioning divisions bolsters internal auditing

25

Globally Expanding Environmental Management

26
28

Fourth Environmental Action Plan
Energy Saving/Prevention of Global Warming

29

Compliance·Ensuring Compliance as Toyoda Gosei Group
·Educational activities for the sake of planning acknowledgement andunderstanding of compliance

Risk Management
·Practical measures concerning information security and improvement of
employee consciousness of it
·First break/restoration and early response from the Disaster Countermeasures
Manual31
32

Social Report
16

18

21

22

Relationship with our Customers
·Quality policy·A quality assurance system that is consistent from development through production·Expanding all manufacturing operation to office employees aiming production
process quality control
·Sales activities responsive to customer needs
·Market quality observation and countermeasure promotion
·Customers praise us as a superior supplier

37

Relations with our Employees
·Developing human resource who can think and operate independently
·Fostering a training culture·Enhancement of a system that enables selection of one’s own way of working
·Creation of a system that enables work with peace of mind after retirement
·Creation of a workplace in which the disabled people also can easily do their jobs
·Planning mental and physical health support·Promoting activities to achieve our goal of zero accidents
·Creating a workplace in which it is easy to do one's job through direct dialogues
with unions

Relationship with our Shareholders
·Achievements and rates of return·Suitable information disclosure as an open company
·Appeal to activism and thinking through plant tours

·Further bolstering social contributions activities
·Proactive volunteer activities at overseas sites·Thorough cleanup activities at each plant·Emphasising the importance of traffic safety
·Fully supporting "Ichinomiya Boys and Girls Invention Club"·"Wheelchair doctors" visiting welfare facilities and hospitals
·Club team players held sports classrooms in each region
·Donating soccer tickets to the facilities for disabled people

Environmental ReportManagement Philosophy
·Relationship with our Stakeholders

Involvement in Local Communities

38

·Environmental Policy/Organization for Promoting Environmental Action

·Handling vehicle weight reduction and clean energy
·Energy saving equipment introduction and CO2 emissions reduction
·Thorough logistics in response to quantity fluctuations

Resource Circulation
·Promoting new recycling techniques·Reducing Waste and Materials Discarded·Reduction of packaging materials through shipping carton storage/management
and local production

Environmentally Harmful Substances
·Reduction of environmentally harmful substances and our global response
·Reduction of environmentally harmful substances in the production process

Environmental management·Enhancing actions at Toyoda Gosei Group·Implementation of Environmental Audits
·Establishment of environmental management system at overseas affiliatedcompany
·Promoting environmental education at Toyoda Gosei Group·Variety of activities for environmentally-focused months
·Efforts of the Domestic and Overseas Affiliated Companies
·Toward further dissemination of LED products that are not as harmful to theenvironment
·Begin "afforestation at plant sites"
·Disclosing environmental cost information

Legal Compliance Activity
·Thorough water quality management
·Preserving the atmosphere through a changeover to natural gas
·Proper disposal and storage of equipment containing PCB·Conserving Soil/Groundwater·Taking action toward "Zero Cases of Non-compliance and Complaints" Activities
·Strengthening our waste management system

Third-party Opinion

Financial Report
39

Data Highlights/Consolidated Five-Year Summary
Consolidated Balance Sheets/Consolidated Statements of Income
Consolidated Statements of Changes in Net Assets/Consolidated
Statements of Cash Flows

Relationship with our Suppliers·Basic Procurement Policy
·Holding a procurement policy explanation session
·Tackling quality improvement, compliance·Strengthening our collaboration with suppliers·Promoting green procurement

Corporate Data
45

Global Network／Directors structure
Company Profile／Stock Information

2

TOYODA GOSEI REPORT 2009
Message from the President

We boldly confront changes withthe growth of worldwide company
as our goal
President

Hajime Wakayama
Respond to Environment Changes
Due to the world economic crisis that began last year
many industries, especially in manufacturing, continue tobe in a serious situation. Our company as well has beenaﬀected and has experienced a downturn in income andproﬁts as the consolidated achievements for ﬁscal 2008
were sales of 546.3 billion yen and ordinary income of 12.1
billion yen.
Due to these harsh circumstances, we have been actively
looking at corporate structural reform to improve
proﬁtability. All the Toyoda Gosei Group has beenendeavoring the best cost cuts and increased eﬃciency
based on the "3 Gen-ism" ("Genchi", "Genbutsu", and"Genjitsu", which are translated as "actual locations","actual materials" and "actual situations", respectively)
through "Urgent Revenue Countermeasure Committee"
set up in November 2008. We have revised our corporate
structure for more rapid decision-making andimplementation with strengthened technologicaldevelopment systems. This will provide us with aframework and system which enables us to eﬀectively deal
with future environment changes in the international
community.

Consolidate Corporate Foundation as a Technology Company
In light of advances in the new era, it is necessary to make3

strategic moves at this time and particularly in newtechnological development. It is technology that has
supported our company. With its advancement, we haveachieved successful product development and production
systems, which we believe have gained customer trust.
Technology is a great asset for us and is indispensable increating corporate value for the future. To this end, ourcompany’ s manufacturing wisdom and spirit of challenge
are combined and have been an engine for establishing us
as a global system supplier. While reaﬃrming our corporate
principals as a technology company, consolidating
manufacturing capability is also required for the modern
age. More speciﬁcally, we gain in global competitivenessby speeding up development of products andmanufacturing technologies to meet expanding demand
for low-priced products from developing to resource-richnations. In addition to the existing "Kitajima TechnicalCenter", we have established the "Miwa Technical Center"and star ted full operation in 2009 to improve theenvironment for research and development on our
mainstay products, automotive parts. Additionally, we aim
to e x p a n d t h e m a r k e t fo r L E D p ro d u c t s t h ro u g hdeveloping high luminance, high quality products andhome use lighting ﬁxtures. We believe this accumulationof technologies will ensure a stable base for the company.
Meanwhile, we aim to face the challenges required in
becoming "a company with reduced dependence on oil"by looking ahead to future business through research anddevelopment in ﬁelds such as in alternative biofuels whichdo not compete with food supplies, or improving recycling
technologies. These technologies will contribute not only
to business growth but also the protection of theenvironment and securing resources.

activities are spread through the entire Toyoda Gosei
Group. Aiming to be an essential corporate member of thecommunity, we work hard at playing a responsible role asa public entity.

Foster "Manufacturing Professionals"

To Take a Solid Step Toward the Future"Manufacturing" is built on reliable knowledge andextensive experience. It is essential to create a working
environment which allows the employees supporting ourbusiness to be able to exercise and develop theirindividual abilities. As well as the essential transmitting of
the extensive technology and knowledge our company
has developed over time on to the next generation, wemust maintain an environment and systems to pursue newideas or values and enthusiastically foster or educate
motivated human resources as "manufacturing
professionals".

Because of the diﬃculties in predicting coming economic
circumstances, we must take solid steps toward the futureby optimizing our wisdom and knowledge. Therefore, weshall meet the challenge of being a global company
centered on technology while striving to continue oﬀering
reliable products and services.
Although we have plans and measures for both long andshort terms, we think it is essential to focus on what we
can do in practice now to take a step toward the future.
We mark the 60th anniversary of the founding of ourcompany this year. The all-hands project "Aﬀorestation atplant sites" has the purpose of creating a sense of unity
among participants and the best possible green environment
at a factory while encouraging interaction with the local
community. We plan to plant trees at our Heiwacho plant andlikewise at other plants in the future.
Finally, I would like to thank our shareholders, customers,clients, all those involved in local societies, our employees,
and their families and ask for your continued guidance andsupport.

To be the Best Manufacturer in the Field"Manufacturing" is the base of the industry and ourmanufacturing competence reﬂects our corporate
capability. The basics of TPS (Toyota Production System)
eﬀectively cuts unnecessary production cost and improves
production eﬃciency. We aim to be the best overall in
selected manufacturing ﬁelds with highly eﬃcient new
product start-ups in our major ﬁelds of resins, rubbers and
LEDs.

All-Out Effort on Corporate Social Responsibility (CSR) Activity
Not only in business, but also in CSR activities, we make anall-out eﬀort. The thoroughness of compliance, corporate
governance and promotion of environmental conservation4

Supporting a technology based enterprise“Manufacturing” and“Human resource development”
TOYODA GOSEI REPORT 2009

SpecialFeatureThe fundamental principle of our technology based company is the development of technology thatwill be used by the next generation from a broad range of perspectives and new concepts.
Simultaneously, the development of human resources who can create that technology and widely
apply it will be essential.
"People make creations, and creations make people grow."
Manufacturing and human resource development are directly connected with our company's future,and their further strengthening is crucial. We are actively planning the establishment of both superior
product development and human resource development that will lead the next generation throughnewly created facilities such as the "Miwa Technical Center" established in April of 2009, equipment,
and an original training curriculum.
Especially during the present recession we must return to our origins as a manufacturer and entrust
our future to these two elements.

Sites that improve development and manufacturing technology
and pursue highly safe technology
There are two objectives for the establishment of the "Miwa TechnicalCenter" that will serve as the second site in domestic for manufacturing
development.
One is to focus on the next generation and plan the enrichment ofprogressive development and research with a standardized system that canhandle everything from the planning to the development of materials,
products, and production technology. This has the important goal of total
optimization and improvement of factors such as quality, production
systems, and costs by conducting manufacturing development in the mostare the core of our company to reaﬃrm the notion that our point of origin
lies in manufacturing as well as serve a signiﬁcant role as the site of
manufacturing technology education.
The other is further pursuit of automobile safety. We are planning theenrichment and strengthening of research development and evaluation
systems to improve the safety of our products from the perspective ofprotecting both passengers and pedestrians. Within the center we will
enhance the latest evaluation equipment such as state of the art airbag
collision simulation testing machine and staﬀ will conduct development
and research toward the provision of a higher level of safety.

ideal environment. Also, this will promote the self-reliance of facilities that
Message from Executive

By ﬂattening from planning through production
technology each process that had beenpreviously divided between each division wecan plan innovative development and research,and our ability to concentrate on manufacturingthat leads to greater quality and satisfaction isincreasing. Because of this, the staﬀ in charge isrequired to have high level development ability
that takes into consideration all production
processes. At the same time, we feel that
because communication between staﬀ, broad
perspectives, and ﬂexible conceptual power isessential, the cultivation of the abilities oftechnical development staﬀ is crucial.

The newly completed Miwa Technical Center
5

Executive Vice President

Muneo Furutani

Diverse educational training suited for every division and level,from the knowledge education to self-education
In our company's human resource development we are improving theabilities of individual employees with training and seminar suited for eachdivision and rank. For the training and seminar we have prepared diverse
curriculum concerning not only everyday work but also compliance,
corporate ethics, and the environment as part of a plan to thoroughly
implement these things in our knowledge and actions as corporate citizens.
There is much variety in the content of the training, ranging from theacquisition of basic knowledge to self-education and skill improvement, andour training facilities are equipped with both big size hall for large scalelecture and training, as well as conference and counseling rooms forsmall-group needs. Also, as a global corporation, it is necessary to provide

language training for employees to be transferred overseas as well as
education for foreign trainees. We have established a global training room,
where education can be conducted using simultaneous interpretation as
well as lodging facilities.
This human resource development is not just to promote manufacturing but
to cause an awareness of the potential abilities of people have such as broad
perspectives and rich concepts, making it a place where people who candevelop themselves are cultivated.
For the sake of regional and international society, we develop superior
human resources and strive to turn out creative "bearing the future".
Message from Executive

On the job training was originally the core ofdeveloping human resource in manufacturing,
but at our company a wide range of knowledge
and skills that cannot be acquired onsite arelearned through training and courses. In themodern era there are instances in which valuing
experience alone is not suﬃcient preparation,and it will be necessary to make advancements
in not only the human resource developing but
also people in general. In this modern era of
rapid change it is important to "think andlearning independently", and we feel that thearrangement of a system and environment thatare responsive to the individual initiative of
employees is one point of future humanresources development.

Communication Training

Executive Vice President

Tsuneji Obara

Overseas trainer training
6

TOYODA GOSEI REPORT 2009

Report by Business Unit
The pillars of our operations are as follows; "to develop and oﬀer value added products, perfect and advance our manufacturingexpertise by building upon the basics and continue to enhance systems for an optimal global supply network." As we tackle the creationof appealing products, by building upon the basics, we will strive to develop further markets using our advanced technical ability.

Business Report

Interior and Exterior Parts

Body Sealing Products●Instrument Panel Modules and Components●Interior Parts●Exterior Parts●LED Applications●Car Accessories●Glass Run●Door Weatherstrip●Opening Trim Weatherstrip●Luggage Weatherstrip

Safety System Products●Airbags●Steering Wheels

Functional Parts●Fuel Tank Module Components●Power Train Parts●Chassis and Drive Train Parts

Optoelectronic Products

General Industry Products●LED lamps/chips●LED lighting●Communications Equipment Components●Air-conditioning Products●Home-related Components●Construction and production Machinery Components■ Sales by Business Unit
General Industry
Products 1.5%

Optoelectronic
Products
3.7%

Safety System
Products
30.5%

Functional
Parts
19.1%

7

Interior andExterior Parts
29.0%

Body Sealing
Products
16.2%

Fiscal 2008
Percentage ofnet sales (%)¥billion

158.3

29.0

88.7

16.2

104.4

19.1

¥billionInterior and Exterior Parts
Body Sealing Products
Functional Parts
Safety System Products
Amount of Automotive Parts
Optoelectronic Products
General Industry Products
Amount of Non-Automotive Parts
Total

Fiscal 2007
Percentage ofnet sales (%)

Year-on-year
rate (%)

192.0

29.0

- 17.5

115.9

17.5

- 23.5

126.9

19.2

- 17.7

166.5

30.5

196.2

29.6

- 15.1

517.9

94.8

631.0

95.3

- 17.9

20.4

3.7

21.9

3.3

- 6.8

8.0

1.5

9.5

1.4

- 15.9

28.4

5.2

31.4

4.7

- 9.6

546.3

100.0

662.4

100.0

- 17.5TOYODA GOSEI REPORT 2009

Interior and Exterior Parts Business Unit
Highlight of ﬁscal 2008

The establishment of a Manufacturing Division Ⅲ
specializing in the commoditization of LED products

We took an across-the-board reduction in automobile production as an opportunity
Business Reportfor change. We returned to our starting point in manufacturing, exhaustively
inspected the workings of the manufacturing process, and eliminated waste andloss; through this we increased our production capability. Precisely because thecurrent state of aﬀairs is diﬃcult, we are bolstering our development system andCockpit modules
Applying technical and know-how cultivated until now and promoting modulization.
Along with improving interior sensation of unity and quality, we have succeeded inlarge scale cost reduction.

concentrating our eﬀorts on manufacturing of products with prospects. In particular,
we are expanding development more proactively than before for environmentally
related matters including lightening, weight reduction, and recycling. Also we aremoving into an era of lessened dependence on fossil fuels. With the development of
substitute materials that have little or no eﬀect on food demand or supply, we ﬁnd
ourselves faced with the challenge of ﬁnding hidden or unknown possibilities that

Radiator grilles
The development of radiatorgrilles corresponding to millimeterwave radar that can detectobstacles ahead and alert
passengers of danger.
Console boxes (double door)
Developing our original structured console box thatyou can open and close the door from both driverand passenger seat smoothly.

do not revolve around the interior/exterior framework process.
We established a Manufacturing Division Ⅲ within our Business Unit which
specializes in the commoditization of LED, development of products that allow for
the coexistence of the environmental and design factors of automotive LED products
and residential LED illumination.

Fiscal 2008 (consolidated)
Net sales: 158.3 billion yen
Percentage of net sales: 29.0%

Body Sealing Business Unit
Highlight of ﬁscal 2008

Development and mass production of the world's ﬁrst light weight opening trim
Beginning production at the new Mexican production site, the fourth of its kindin North America

●
③
●
①

Due to our proactive work on weight reduction resulting in a connection between●②

fuel eﬃciency and price reduction, we were able to begin mass production in ﬁscal
2008 of the world's ﬁrst lightweight opening trim. Also we aim to establish mass

①Glass Run②Opening Trim Weatherstrip③Door Weatherstrip

●
①
●
②

production of the technologically diﬃcult solid gum recycling and double our rateof recycling in ﬁscal 2009. Meanwhile, for the sake of further advancing theimprovement of extrusion molding, we will implement in diversiﬁed analysis of
the state of manufacturing by exhaustively implementing "Visualization", and●③

improve yield ratios.
In October of 2008, our new body sealing company TGASMX (Mexico, San Luis
Potosi) began mass production, making it the 4th production site in North

We are always proposing the most suitable
door seal structures in response to various
door function and design needs

America. We established a global system through our 14 overseas production sites.

Light weight opening trim
for compact cars
Achieved unprecedented
weight reduction withdevising rubber materials
and metal inserts

Through the reorganization of production systems at each site we will create astronger corporate structure.

Fiscal 2008 (consolidated)
Net sales: 88.7billion yen
Percentage of net sales: 16.2%

8

TOYODA GOSEI REPORT 2009

Report by Business Unit

Functional Parts Business Unit
Highlight of ﬁscal 2008

Development and mass production of the ﬁrst plastic fuel inlet pipe in Japan
Integrating and arranging produced commodities at each plant andimproving eﬃciency

Business Report

As a result of our proactive development of fuel system components, we were theFill limit
vent valves

Fuel caps

ﬁrst in Japan to succeed in changing over to plastic fuel inlet pipes which are
ordinarily metal and began their mass production. We will make use of the wide
ranging weight reduction and low environmental burden, our specialities, and inﬁscal 2009 we will focus our eﬀorts on expanding orders for the same sort ofFuel hoses and tubes
Fuel Tank Module Components
We are promoting the production of goods thatprioritizes the development of high performancecomponents centered on those surrounding fueltanks as well as environmental regulations

Plastic fuel inlet pipes

products. We will continue to have as our policy the development of materials andproducts for alternative energy source automobiles such as hybrid systems, electricvehicles, and fuel cell powered vehicles.
Amid this ongoing diﬃcult economic state of aﬀairs brought on by the worldwide
recession, we take the changing of models on existing products as an opportunity,
by exhaustively reevaluating the actions of domestic and foreign investment sites,
and arranging or integrating produced commodities. We aim to establish a
speedier and more eﬃcient production and supply system.

(Rubber)(Plastic)
Constant velocity joint boots

Brake hoses

Engine cooling hoses

Hoses & Boots
Developing boots components that support brake system,
running and steering systems of engine

Fiscal 2008 (consolidated)
Net sales: 104.4billion yen
Percentage of net sales: 19.1%

Safety Systems Business Unit
Highlight of ﬁscal 2008

Development and mass production of the world's ﬁrst rear-end impact airbag
Development and mass production of the world's ﬁrst backseat center airbag
Beginning production at our third Indian production site

Curtain airbag(the front and rear seats,both sides)

Driver-side airbag
Knee airbag (driver-side)
Passenger-side
airbagWe are developing and mass producing of the world's ﬁrst rear-end impact airbag
to help realize the goal of a "360 implementation." We also began mass productionof backseat center airbags. There are up to more than 10 airbags that can beinstalled in one vehicle, including side airbags and curtain airbags. In addition, weRear-end impact
airbagSeat cushion Airbag(passenger-side)
Side airbag (driver and passenger-side)
Airbags
Airbag systems that along with seatbelts protect passengers frommyriad collisions, such as those from the front, side and rear.

are introducing a collision simulation testing machine that can closely evaluate
real car crashes which help us advance in collision safety development technology.
Furthermore, we are focusing our eﬀorts on cost reduction through design
innovation, as well as global responsiveness. We will proactively expand fusion
technological development through both preventive safety technology andpre-crash system which are to avoid collisions in the future.

9

Steering Wheels
Airbag handles with heightened operability
due to their collection of switch types

Backseat Center Airbag
Airbag due to protect passengers insitting opposite side from collisions

In April of 2008 we established the new safety systems business company TGIN

Fiscal 2008 (consolidated)(the 3rd Indian development site, located in the Rajasthan state in northern India),

Net sales: 166.5 billion yen

and production there has already begun.

Percentage of net sales: 30.5%

TOYODA GOSEI REPORT 2009

Optoelectronic Business Unit
Highlight of ﬁscal 2008

Setting a new record for production and sales of LED chips
Doubling the sales of laptop computer packages

White SMD type LEDs

Due to the introduction of the top class LED chip in the industry, we set sales andBusiness Report

production records in October of 2008. Afterwards, we were unable to avoid the
production reductions that were necessitated by the adjustments in production
from clients due to the worldwide recession, but beginning with ﬁscal 2009 a

LED backlight for laptop computers

recovery seems imminent. Also, in the laptop computer market which has been
positioned as the principle market starting in ﬁscal 2007, the package's long
life-span and high brightness have been recognized by customers and sales havenearly doubled. The changeover to LED backlights for laptop computer is estimatedLED backlight for meters

to increase in ﬁscal 2009 to approximately 40% from approximately 6% in ﬁscal
2008, and by planning further expansions of operations such as taking advantage of

Image of LED lighting=LED system downlights

this trend and concentrating our eﬀorts on customer-in activities we aim to double

We are making progress on thedevelopment of residential LED general
illumination systems

in comparison with the previous year the sales of laptop computer packages.

Fiscal 2008 (consolidated)

Also, in collaboration with the Interior and Exterior Parts Business Unit we will

Net sales: 20.4billion yen

concentrate our eﬀorts developing LED illumination systems for residences.

Percentage of net sales: 3.7%

General Industry Products Business Unit
Highlight of ﬁscal 2008

Expanding mobile phone cases orders in China

Regarding our mobile phone cases, one of our main products, production,
supplying, and technological capacities have been evaluated, and last year new
customers were attained. This has smoothly expanded production quantities in
China and we predict a doubling of sales compared with the previous year in ﬁscal

Mobile phone cases
Productization of the precision molding technology and surface finishing technology
which were cultivated until now .

2009. The mobile phone market in Japan is not really undergoing much growth,and for the time being our policy is to focus on the Chinese market. There is muchproduction potential for our subsidiary company and production site in Tianjin and
it is capable of handling further production increases.
There is currently no increase in production for air puriﬁers forecasted for ﬁscal

Air purifiers
We handle from development and planning to production,and supply our products to air conditioning manufacturers.

2009 due to the business slump in electronic production, and production will be
the same as the previous year. Because we are streamlining our corporate
structure, we must implement focus and selection and will channel those energies

Fiscal 2008 (consolidated)

into residential parts and materials as well as construction machinery that makeNet sales: 8 billion yen

use of automobile technology.

Percentage of net sales: 1.5%

10

TOYODA GOSEI REPORT 2009

Report by Region

We always aim to come out on top manufacturing using our global network capable of the best procurement in the world.

Business Report

Headquarters
Supervising company /Research and Development
Operating Company
Other

Japan

North America / Asia and Oceania / Europe and Africa

Development and mass production of theworld's first and Japan's first products

Establishment of 2 production sites
In ﬁscal 2008, we established 2 production sites, the safety systems

Fiscal 2008 sales were 320.9 billion yen (down 16.7% from the previous

business company TGIN (Northern India, Rajasthan state) and the bodyyear) and operating proﬁts were 3.4 billion yen. The cause of thissealing company TGASMX (Mexico, San Luis Potosi state). Our global

decline in proﬁts and lower sales for our automotive parts operations

network consists of 45 facilities in 16 nations and regions around thewere ﬂuctuations in product prices and product structures and theworld excluding Japan.

impact of ﬂuctuations in the exchange rate. Even amid this diﬃcult

Sales in North America totaled 101.1 billion yen (down 28.7% from thestate of aﬀairs, we continue to proactively work on the research andprevious year) and operating proﬁts were minus 2.9 billion yen. Evendevelopment that will be important in the future, such as thethough Asia and Oceania were assisted by the bullish market in Asia,

development and mass production of the world’s ﬁrst "rear-end impact

sales there were 96.6 billion yen (down 2.8% from the previous year)

airbag" and "backseat center airbag" as well as Japan's ﬁrst "Plastic

and operating proﬁts were 14.7 billion yen. Sales in Europe and Africa

fuel inlet pipe".

were 27.7 billion yen (down 22.8% from the previous year) andoperating proﬁts were 0.4 billion yen.

■ Sales by Region
Europe and Africa
5.1%

Fiscal 2008
Percentage ofnet sales (%)¥billion

Asia and
Oceania
17.7%
North
America
18.5%

11

Japan
58.7%

Fiscal 2007
Percentage ofnet sales (%)¥billion

Year-on-year
rate (%)

Japan

320.9

58.7

385.4

58.2

-16.7

North America

101.1

18.5

141.9

21.4

-28.7

Asia and Oceania

96.6

17.7

99.3

15.0

-2.8

Europe and Africa

27.7

5.1

35.8

5.4

-22.8

Total

546.3

100.0

662.4

100.0

-17.5

Toyoda Gosei upholds and promotes the corporate philosophy of "steady growth through innovation", "customer satisfaction","humanistic corporate culture", "good corporate citizenship", "respect for the environment" and "ensuring it in sync with the global
community".
We will continue to conduct business activities in order to meet the expectations of our stakeholders, as well as strive to be "a

TOYODA GOSEI REPORT 2009Management Philosophy

global system supplier who impresses customers by oﬀering attractive products".
Management ReportManagement Philosophy
Steady growththrough innovation

Customersatisfaction

Humanistic corporate
cultureGood corporate
citizenshipRespect for theenvironment

In sync with theglobal community

Relationship with our Stakeholders

Customer

Employee

Toyoda Gosei Corporate Goal
The "Customer Comes First" andUnder the philosophy of "Safety

Global supplier of automotive
and technology systems –provide products that truly
impress customers"Quality First" are the concepts withwhich we carry out our business
operations, while aiming to provide
appealing products and services thatsatisfy and impress our customers.

Comes First", we are seeking to create aworkplace where employees can staymentally and physically healthy while
they work, and enjoy a sense of
security while building up a creative
ability and a spirit of challenge.

Shareholder

Supplier

We try to direct our eﬀorts towards

We present procurement plans/policies

stablethat aptly reﬂect business and market

dividend

payouts

toourshareholders and a fair and proactive
disclosure of information as well as toLocal
Community

trends, and are working toward establishing
relationships that foster mutual growth/development with suppliers.

enhance corporate value.
Aiming to become a "trustworthy,
respected corporate citizen", we areengaged in a range of activities forcooperation/coexistence with local
communities.

12

TOYODA GOSEI REPORT 2009

Corporate Governance
We are planning sound management and organizational eﬃciency promotion to create a corporate
structure that can swiftly react to changes in its environment.
Highlight of ﬁscal 2008

Strengthening the auditing implementation internal checking system in functioning divisions
Holding the 1st Internal Auditor Training

Management Report

Achieving Prompt, Eﬃcient and Sound Business Management
We are conducting the enrichment and strengthening of corporate■ Diagram of the Corporate Governance Systemgovernance that has as its goal sound corporate management of which the

Shareholders' Meetingmost signiﬁcant matter for management is the stable improvement of

Appointment

Appointment

shareholder value. Therefore, for the sake of meeting the expectations of all
stakeholders including stockholders and customers, we are building and

Board of Directors
Director

Auditing

Appointment
Cooperation

Board of Auditors
Auditormaintaining an organizational system that can swiftly and appropriately
respond to environment changes and a fair, transparent, and soundmanagement system.

Supervision

Representative Director

Management Committeeby law. In addition, we have also developed/established an internal control

Committees on Various Functions

Committee on the ethics of corporate activities

business judgments; (2) eﬃcient business operations; and (3)eﬀective

Export management committee

supervision and auditing processes. Additionally, we have shortened theEnvironmental committee

terms of directors to one year in an eﬀort to develop a ﬂexible management

Internal Auditing Division

Committees

operations, reinforces internal auditing, in an eﬀort to achieve; (1) apt

Central committee on health and safety and others

Accounting Audit

Accounting Auditor · Auditor

board of directors, a board of auditors and accounting auditors as mandated
system that holds discussions on important issues, checks business

Cooperation

ReportWe have set up the necessary functions including shareholders’ meetings, a

Internal Audit

system that can respond swiftly to changes in the business environment
and to further clarify the management responsibilities of directors.

Auditing

Various Functions and Business Divisions

Implementation of auditing in functioning divisions bolsters internal auditing

45people

For the sake of checking whether laws and corporate ethics are being

Along with the creation of this system, we have implemented the 1st audit

observed at our company, we are conducting internal management andtraining for functional divisions and plan to step up this training from 2009 as well.

supervision based on corporate laws. The internal auditing that had beenAlso, we prepared internal controls relating to ﬁnancial reporting based on

conducted by the Auditing Division was implemented in ﬁscal 2008 in the

Financial Instruments and Exchange Law that went into eﬀect in ﬁscal 2008,

General Administration, Human Resource, and Accounting Divisions, and a

and submitted our "Internal Controls Report".

bolstered a system that checks whether auditing is able to observe
everything down to smaller details, such as classiﬁed information
management methods. There is a mechanism in place to collect the content
of internal auditing within the functional divisions into the Auditing
Divisions, through which we have built management/supervisoryorganizational systems.
13

Participantsin Internal Auditing
Corporate Training MeetInternal Auditing Corporate Training Meet

We aim to be good corporate citizens and are moving forwardwith the establishment of compliance.
Highlight of ﬁscal 2008

The establishment of our Group Charter for Business Ethics is not only in Japanese but also in both English and Chinese
which are both new additions, to foster a shared awareness among the Toyoda Gosei Group
Conducting a compliance adherence rate survey of all employees
Distribution of Toyoda Gosei Group
Charter for Business Ethics

TOYODA GOSEI REPORT 2009

ComplianceManagement Report

9 Overseas:
38
companies

Ensuring Compliance as Toyoda Gosei Group

Japan:
companies

Toyoda Gosei strives for truly comprehensive compliance, and seeks toensure that each and every employee complies with all laws and regulations
not only from the standpoint of obeying the law but also from thestandpoint of corporate ethics.
In 1997, Toyoda Gosei established a "Committee on the Ethics of Corporate
Activities" with the President serving as chairman and all company

Toyoda Gosei Group Charterfor Business Ethics

Toyoda Gosei Guidelines
for Business Ethics

executives as members. A legal liaison oﬃcer was also appointed withineach division.
In ﬁscal 2008 we established the "Toyoda Gosei Group Charter for Business
Ethics" to maintain shared values and behavioral standards at Toyoda Gosei
Group and planned to establish a compliance foundation at all groupcompanies domestic and overseas. At our company we have revised the"Toyoda Gosei Guidelines for Business Ethics" that serves as concrete
behavioral guidelines with respect to compliance for all our employees andare distributing it to them.
Also, for when employees are faced with compliance problems during
everyday operations, we have established internal and external complianceconsultations services to solve the problems quickly.

Issue the "Toyoda Gosei Guidelines for Business Ethics"
which is based on our management philosophy
Clarify the code of conduct for employees

Establish a "Committee on the Ethics of Corporate
Actions" with all company executives as members
Discuss and make decisions on important issues regarding compliance

Hold "legal liaison conferences", whose members are
made up of representatives from each division
Aim to disseminate compliance and legal information throughout the entire Toyoda Gosei

Implement legal aﬀairs / compliance training
Compliance educational activity

Consultation services on compliance and sexual harassment
established inside and outside the company
Respond to compliance-related issues

Educational activities for the sake of planning acknowledgement and understanding of compliance

Conducting
a compliance survey

8,300people(All Employees)

We are expanding various educational activities pertaining to theemployee compliance consciousness through reform activities based on an

acknowledgement and understanding of compliance by all employees. In

analysis of the results of this survey.

ﬁscal 2008, in addition to conducting level and risk speciﬁc employee
compliance training, we spread compliance news and topics throughcompany newsletter and bulletin boards "Compliance Communications".
Also, we are working to put together lectures about the establishment of
the Lay judge system beginning in 2009 and hanging posters to create acompliance culture in order to foster compliance consciousness.
In ﬁscal 2008 we made questioning more detailed in order to be grasp therate of understanding through the entire company and carried out acompliance understanding survey targeting employees. We plan to improve

Lay judge system lecture

Compliance culture creation poster

14

TOYODA GOSEI REPORT 2009

Risk Management
We strive to strengthen risk management through employee training, product assurance activities,
information security measures and disaster countermeasures.
Highlight of ﬁscal 2008

Improvement of internal audit accuracy against information security andregulation of conﬁdential information to outside

Management Report

Practical measures concerning information security
and improvement of employee consciousness of it

Employee moral awareness improvement
The threat of information security problems do not largely originate

At our company, we established the "Security Management Representative"externally" but "internally" within the company or from businessMeetings" in which each division director participates under theconnections, and the majority of them are caused by people. Therefore as a"Committee on the Ethics of Corporate Actions" and thoroughly implements

way of "dealing with such people" we are dealing with tackling theinformation pertaining to security measures.

establishment and honoring of rules such as handling and storage methods

In ﬁscal 2008 we made as part of our guidelines the "Security Management

for classiﬁed documents as part of information leak prevention and security

Act" and "Operative Standard for Information Systems" and are promoting

management. We are also planning a more stringent observation of

the strengthening of practical measures and the improvement of thecomputer use through software license management and state checks frominformation security consciousness of all our employees.

operations logs, as well as the improvement of employee moral awareness.

Strengthening information security measures
We are continuing to carry out the "Prevention Measure for Negligent Leaks"
stemming from the data encryption implemented in ﬁscal 2007. The"Prevention Measure for Malicious Unauthorized Leaks"stems from things
such as the acquisition of system usage records, thorough dissemination ofknowledge of rules, and activities to improve rule awareness. Also, we
implemented at each division the use of check sheets for self-inspection of
their handling and management methods of secret information.
We also improved system utilization history and a USB memory removal
management ledger to regulate conﬁdential information to the outsidewhen conducting internal audits by the General Administration and IT
Promotion Division.

First break/restoration and early response
from the Disaster Countermeasures Manual

Practice
training

5timesWith "Life Comes First" and "Quick Restoration" as the fundamentals of ourdisaster countermeasures, we are strengthening anti-seismic reinforcement ofequipment and everyday monitoring activities as preemptive measures against
natural disasters,everyday ﬁres and explosions. As preparation for large scale
earthquakes in particular, we have established an "Emergency Earthquake Report
System" at each site to ensure employee safety and safe evacuation. Also, weestablished the "Toyoda Gosei Disaster Countermeasures Manual" that anticipatesemergencies and indicates a procedure of ﬁrst break/restoration response for thesake of minimizing injuries. We are also constructing a system for when incidents
occur that can conﬁrm the safety of about 20,000 employees and their family■ Examples of Measure Enhancement
Division
Prevention for
negligent leaks

Soft ware

Implementation Issues● Data encryption of all PCs● E-mail security reinforcement

Hard ware● Increase in the number of surveillance cameras

employee skills that will be necessary for quick restoration.
■ Organizational Chart for Emergency Disaster Countermeasures
Task force setting
level decision meeting● Inspection for things taken out (inspect twice a month)members as well as provide databases of replacement equipment, locations, andWatchout/
monitoring headquarters● Wire setting for ﬁxing PCs

Prevention formalicious
unauthorizedleaks・Lap-Top PC ・Desk-Top PC ・external HDD● Reinforcement in access privileges to the ﬁle server
Soft ware● Restrictions on things taken out / enhancement of check function● Acquisition and Monitoring system usage records and access records.

Starting team
(Investigating team)District self-defense
disaster prevention teamStaﬀ support
squad

Local support
squad

Rescue andaid squad

Safetyconﬁrmation squad

Information
squad

Qualityassurance squad

Material
securement squad

Utility squad

15

Process
restoration squad● Onsite inspections for each division

Logistic squad● In-house education of security management

Progressmanagement squad● Simultaneous inspection of security consciousness for all employeesLife support task force

Local uniﬁcation squad

Customer
response squad

Moral measure

Production restoration task force

District task force● Prevention for unauthorized access● Review of Security Management Act

Emergency task force

TOYODA GOSEI REPORT 2009

Relationship with our Customers
The "Customer Comes First" and "Quality First" are our concepts
in aiming to provide appealing products and services.
Highlight of ﬁscal 2008

Expanding production process quality control to back oﬃces (the Administrative and Technical Divisions)as well to improve work quality
Aiming for a zero defect production process and expanding targeted quality engineeringwith the goal of robust design*1 throughout the entire company

Quality Policy"post-manufacturing = our customers" and utilize mutual
cooperation to provide excellent products and services that will win
trust and satisfaction of our customers.

Social Report

Everyone shall bear in mind the concepts of "Quality First" andExpanding all manufacturing operation to oﬃce
employees aiming production process quality control
All employees at our company act based on the principle of "Customer Comes First"
and we aim to perfect quality assured production processes for all our operations.
Production process quality control means that "quality is built in during the

A quality assurance system that is consistentfrom development through production

production process", and is the idea on which all our work is based.
Working from the idea of "No defects shall be tolerated in any production process toensure that there will be no defects in post-production (i.e., in the product given to

At our company, we aim to "provide appealing products and become acustomers)" in manufacturing, we have as our goal a robust design to prevent

global system supplier that will truly impress our customers."

against environmental changes and manufacturing scattering, are promoting theWith regard to quality assurance, we operate under the consistent quality

expansion of quality engineering throughout our entire company, and are of course

assurance system from development to production under our quality policy.

aiming for a zero defect production process for our mass produced goods as well as

Speciﬁcally, all our plants have obtained ISO9001 and ISO/TS16949

a defect-free production process from the very ﬁrst day of production for a newcertiﬁcation which is the international standard of quality management

product. Furthermore, we are expanding production process quality control ideas

system. Also each plant has its own quality control goals to produce

and know-how that have taken root at the assembly line (Manufacturing Division)

appealing products through TQM*2 activities.

expanding to the work of the back oﬃces (Administrative and Technical Divisions)and are tackling operations reform throughout the entire company so that they all*1 Strong product designs that come with little unevenness in quality and insusceptible to usage environment.
*2 Total Quality Management

can make judgments on site about work quality.

Staff Production Process Quality Control Exhibition

Observational rounds through the production
process by the President■ Production process quality control that aims for a zero defect production process■ TQM Activities

・Improvement of drawing quality
・Robust design・High reliability design
Designthat is easy to make

Adopting Excellent Design High-Quality Components& Materials
Drawing Practices

Customer ﬁrst

Production
Process Quality
Providing the Conditions
Control
Early Identiﬁcation,

TQM
Continuous
improvement

Procurement

MarketHaving everyone
participate

Needed to Produce
Pre-Production
High-Quality Items Preparations

Early Response

Maintenance & Management

・Establishing robust
qualityproducts condition
・Automation

Production

16

TOYODA GOSEI REPORT 2009

Relationship with our Customers

Award

Social Report

Sales activities responsive to customer needs

Customers praise us as a superior supplier 10companies

The role of the Sales Division stands at the front lines of our company. They

Our products are delivered to automotive manufacturers of various

listen to needs and development information from key members incountries in the world and support its basic performance of the automobile.

technology and improvement, and connects those needs with sales

Each manufacturer commends an excellent supplier every year and Toyoda

promotion. While cultivating an amicable relationship with customers, we

Gosei has received commendations from a large number of clients.

have collected and analyzed diverse information such as necessary mattersand problems essential to customers. While sharing that content with

■ Award for quality in fiscal 2008

relevant internal departments, we respond to the diverse needs fromAward names

customers and make unique proposals to build a relationship of trust with

Quality Corporation Award

those customers.

QUALITY AWARD 2008TGKY

QUALITY AWARD 2008

TGMINTO

Market quality observation andcountermeasure promotion

Awarded company Origin of commendation
TGNAI(Indiana plant on TGMO)

TG's Quality achievement Q1

TGRT

AAT (FORD)

Quality-Delivery achievements A rank

TGSSI

KTB (MITSUBISHI)

Tai-Yue Rubber

Tai-yue Rubber Industrial Co.,Ltd
Kuozui MOTORS,LTD

TGCZ

TPCA
(Toyota Peugeot Citroen Automobile)

Good Quality Award (6 companies)

Fu-YueSichuan FAW Toyota Motor Co.,Ltd.

Good Quality Award (7 companies)

Zhangjiagang TGP

Sichuan FAW Toyota Motor Co.,Ltd.

Commendation for achievement on
reducing free repairs

Toyoda Gosei

Toyota Motor Corporation Takaoka Plant

Free repair expense reduction policy
proposal adoption commendation

Toyoda Gosei

Toyota Motor Corporation

Excellent Quality Award
Suppliey Quality Award 2007

We established a system through which whenever quality problems occur inthe market information is conveyed through automotive manufacturers,
then swiftly passed on to the relevant internal divisions, after which causes
are ascertained through such methods as analyzing recalled products, andTEMA(Toyota North America
Supervising Sites)

then measured to prevent a reoccurrence of the problem. At times when it isdiﬃcult to ﬁnd the cause of a problem and its solution at our company, we
team up with the quality divisions of automotive manufacturers, conduct

Case study

tests using test vehicles etc., and work to promote a swifter and more

Protecting backseat passengers during rear collisions

precise prevention of reoccurrences and preemptive measures for our next

There are many collisions from following cars among car crash cases, and in compact

product.

cars there are times when the heads and necks of backseat passengers are damaged.
We developed "rear-end impact airbags" in the world ﬁrst to protect passengers duringcollisions from the rear.
An airbag and its inﬂator (gas generator) are incorporated into the underside of theroof at the back end of a vehicle, and it inﬂates in a downward motion; through this wehave increased safety by protecting the heads of passengers.

Activities for improving market reliability

Rear-end impact airbag (The world’s first)

17With "Humanistic corporate culture" and "Safety comes ﬁrst" as our fundamental principles,
we aim to create a healthy workplace where employees can work with peace of mind.
Highlight of ﬁscal 2008

Publishing the "TG Child-Care and Nursing Care Support Guidebook"
Our company newsletter "TG Times" has received an award of the "Grand Prize" in recommended company newsletter.

correspondence course centered on younger personnel and have planned toSocial Report

Developing human resource who can thinkand operate independently

TOYODA GOSEI REPORT 2009

Relations with our Employees

raise our levels of ability. Additionally, we have sought to ensure the
All our employees share a sense of values that state "as a corporation we areminimum level of English necessary for everyday communication in our

only as strong as our human resources and these resources represent ouremployees being transferred overseas, and have begun oﬀering training sitestrue products".

and opportunities including training camps in ﬁscal 2008. We are also trying

The center of human resource development is on-the-job training. For theto raise the language ability (in English) for the entire company through suchsake of planning and a fostering

methods as developing an index of TOEIC score for the managerial workers.

human resource development

consciousness,we are concentrating our eﬀorts on the preparation of a

For the sake of continuously maintaining human resource development

human resource system and the creation of a training structure.

including these policies, we are concentrating on the advancement of theinternalization of education and a training culture in which superiors cultivate■ Human Resource Systems
A system of group educationthat is separated by position
and function (problem solving,
management)
Actively identify and promoteable personnel from ourworldwide oﬃces and plants
and from younger age groups(opportunities for people intheir 30's to be promoted)

their subordinates.
OJT, which is the foundation of human resource
development / Human development in theworkplace through work experiences thanks tomanagers' eﬀorts
On-the-Job
Training
(OJT)

Group
Education

Self- InitiatedInterview
SystemPersonal
GrowthPromotion*1 Plan, Do, Check, Action

2,200people 1,700people

Basic technicaltraining

Overseas-related
education

Language training

Participants in English Participants in problem
correspondence course
solving training

GL/Section leaders
Subsection leaders
Team leaders
General employees
New employees

Training according to employees' positions
Management training for general managers / division leaders
Management training for GL / section leaders, problem-solving mentoring training
Management training for subsection leaders
Training for team leaders
3 level training, problem solving basics training
Training for new employees

Education for transferred/
local employees

Fostering a training culture

An evaluation and merit system basedon skill and performance that is both
highly rational and easy to grasp

Position title
General managers /Division leaders

GPC activities

Prearranged position rotations to foster
human resource development andinvigoration (career paths, growth as
multi-skilled technicians)■ Training Structure*2

Evaluation and
Merit System

Language training

Educational system
for skills
Educational system forengineers

Position
Rotation

A shared understanding of"challenges for professional
and personal growth"through communication
between managers andworkers*2 Global Production Center

T O P I C S

Inazawa Plant great dining hall cleanup campaign

For the sake of ensuring for all positions that "Problem solving aptitude

The Inazawa Plant employee dinging hall has undergone renewal through repairs and(PDCA*1 based work advancement)" is the fundamental philosophy forcleaning done by the employees . Previously we had entrusted this to specialist

moving work forward, we are implementing training throughout ﬁscal 2009
for all team members [or white-collar workers].
Meanwhile, subordinates nurturing plays a vital role for the managerial

contractors, but we conducted a cleanup eﬀort after thinking that "we should beautify
our workplace ourselves". There are number of expert employees at Inazawa plant andthey renewed everything including the ceilings, walls, and windows by themselves. With
the wisdom and ideas of employees it has the great appearance through such methods asworkers, and in order to orient them toward leading their subordinates, wecreating ﬂowerbeds and LED spaces

implemented communication training program in ﬁscal 2007 and problem

by the dining hall entrance. After

solving leadership training program in ﬁscal 2008.

completion, we independently im-

Also, amid the current globalization, every team member including

plement regular cleanup and the

managerial workers are aiming tocommunicate during everyday

conversation using English. Starting in ﬁscal 2003 we have held English

ring of these activities is expanding
within other plants.

18

TOYODA GOSEI REPORT 2009

Relations with our Employees

Social Report

Enhancement of a system that enables
selection of one’s own way of working

Creation of a workplace in which the disabled
people also can easily do their jobs

While considering the "work/life" balance of each individual employee , weAt our company we proactively strive to employ members with disabilities.

are planning the enhancement of a system that enables employees to choose

We have posted consultants to each workplace and take into consideration

their way of working. We are also oﬀering assistance such as the introductionease of work in our creation of workplaces and will strive to boost theof a short-time working system and the support of aemployment rate by means of reinforcing recruitment activities in the

day nursery on national holidays which fall during our

future.

operating days. And we support working fathers and■ Changes in the employment rate of disabled people

mothers, allowing them to work with greater peace of(%) 3

mind and motivation. We published the"TG Child-Careand Nursing Care Support Guidebook" in ﬁscal 2008
and assist our employee’s child-care.

1.66％

2
TG Child-care and Nursing
care support Guidebook

1

Legally required employment rate of 1.8％
'00

'01

'02

'03

'04

'05

'06

'07

'08 (Fiscal year)■ Changes concerning those who take child-care leave(Person) 40

35

Planning mental and physical health support

20

Mental and physical health are the major pillars of employee health
0

'03

'04

'05

'06

'07

'08

(Fiscal year)

Creation of a system that enables work withpeace of mind after retirement
Starting in April of 2006, we established the "Retiree Reemployment System" andReemployed Person
Retirees(Person)150■ Health Educational Structure
Health Care
Plant managers
General managers
Division leaders /Assistant managers

Supervisors

0

'06

'07

'08

'09

'10

(Fiscal year)

T O P I C S

Our company newsletter has received an award of the"Grand Prize" in recommended company newsletterfrom Nippon Keidanren.
In ﬁscal 2008 our company newsletter "TG Times" received the "Grand Prize" in the
Nippon Keidanren promotion nomination of internal company report selection system.
The planning content and design of the
publication underwent renewal in 2008
under our editorial policy of creating a"lively company newsletter". This content
received acclaim and was a reason why
we received the prize.

19

Mental healthleaders education

Good life
seminar 35

Mental healtheducation
for management
directors

Section leaders
G L

75

Physical healthmanager
education

TL andSubsection leader

Team leader（

Physical health education
at 35 years old

Stress education■ Changes in Reemployed Retirees

health maintenance and promotion within the company.

Mental health (follow-up)
education

are creating a system that enables work with peace of mind after retirement as well.

management, and we are considering various policies to plan mind/body）

General employees

Enhancing the mental health education of management directors
In ﬁscal 2008 we regularly held mental health education sessions for each
employee position, with special emphasis on newly appointed
management directors, division leaders, and assistant managers, bypromoting an eﬃcient workplace operation and smooth communication.
We promote good mental care and planning to enhance counselingprovided by licensed professionals at each operations site.With the numberof consultants declining,the results are steadily beginning to show.

Participants in
Symposium

113people over1,300people

For physical health, from ﬁscal 2007 through 2008 we have conducted

Implementation of manager and supervisor
safety ability evaluations

everyday living health education such as the prevention of lifestyle illnesses

Creating "Safety Aware Personnel" is an awareness building activity thatby targeting 35 year old employees with the holding of a "Good Lifefocuses on cultivating individuals capable of identifying possible "threats"

Seminar 35" to heighten self-health management awareness.Also, we are

as risks by checking all employees and providing guidance to those who

holding symposiums to promote education concerning the prevention ofneed it with respect to this matter. We are also conducting evaluations of

the arteriosclerosis that causes stroke and heart infraction. Industrial

the safety ability of managers and supervisors, and as of ﬁscal 2008 we havephysicians are currently conducting physical education through healthgiven awards to 15 outstanding managers and 15 outstanding supervisors.

consultations targeting employees posted in East Asia.

Social Report

Held "Good life seminar 35"

TOYODA GOSEI REPORT 2009

Participants in
Seminars■ Main Activities in Fiscal 2008
Implementation issues

Under the direct leadership of our president, who is the General Health and
Safety Manager of the whole company. We are driven by two powerfulforces - the "Division for the Development of a Safe Workplace" and the"Division for the Development of Safety Aware Personnel". We are actively
working to achieve our goal of zero accidents.
21 domestic and overseas operation sites obtained
occupational safety management systems
In "Develop a Safe Workplace" we aim to have a workplace with none of thedangerous aspects or causes of danger that are linked with accidents and aretackling the making of our facilities safe, forklift-free activities. Also, we are

Development of Safety Aware Personnel Development of a Safe Workplace

Promoting activities to achieve our goal of zero accidents● Evaluating and working to improve every employee's abilities to ensure safety
1● Improving and commending supervisors' abilities to evaluate aptitude for safety assurance2● Awareness-raising of all employees
・Implementing "danger sensitivity education"3● Safety aware personnel activities for engineers・"Genchi-Genbutsu KY education" and "danger sensitivity education"

4 ● Forklift-free for operations, promoting to separate employees in platforms/passageways from forklift work area
● Conducting risk assessment of facilities and tasks (countermeasures against defects & against stationary condition)
5 ● Prevention measure for metal molds dropped based on the storage speciﬁcations● Standardizing a operational sequence from acceptance, storage and to exchange of metal molds
6● Outworking of anti-earthquake measure and following-ups of the suppliers● Prevention of ﬁre/explosion and reinforcement of daily monitoring activity
Casualties accompanied■ Changes in the Rate of Work Accidents
Rate of injuries resulting ＝ by lost work time × 1 million
Total work hours(rate of injuries resulting in lost work time) in lost work time
1.5

Whole manufacturingindustry
1.05

1.0

Transportation equipment
industry
0.59

moving forward with activities to acquire the OSHMS certiﬁcation in*1

domestic, and OHSAS *2 certiﬁcation in overseas , a common standard for
occupational health and safety management systems. As of ﬁscal 2008 thesites written below have attained this certiﬁcation.
*1 Occupational Safety and Health Management Systems*2 Occupational Health and Safety Assessment Series■ The state of occupational health and safety management systems acquisition
Toyoda Gosei● Heiwacho Plant ● Haruhi Plant● Inazawa Plant● Bisai Plant● Nishimizoguchi Plant ● Morimachi Plant

Domestic Aﬃliates● Ichiei Kogyo Co., Ltd., ● Hinode Gomu Kogyo Co., Ltd., ● TG Maintenance Co., Ltd.,● Chusei Gomu Co., Ltd., ● Hoshin Gosei Co., Ltd., ● TG Logistics Co., Ltd.,

Overseas Aﬃliates● Fong Yue Co.,Ltd.
● Bridgestone TG Australia (Pty) Ltd.
● Tianjin Toyoda Gosei Co., Ltd.
● Tianjin Star Light Rubber and Plastic Co., Ltd.
● Toyoda Gosei Czech,s.r.o.
● Toyoda Gosei (Thailand) Co.,Ltd.
● TG Kirloskar Automotive Pvt.Ltd.
● Toyoda Gosei (Tianjin) Precise Plastic Co., Ltd.
● Toyoda Gosei Texas,LLC

0.5
0Toyoda Gosei
0.00

'00

'01

'02

'03

'04

'05

'06

'07

'08 (Fiscal year)

Creating a workplace in which it is easy to do
one's job through direct dialogues with unions
Based upon our fundamental philosophy on labor management relations, "establishingmutual trust and sharing responsibilities between employees and management " we holddiscussions with the labor union on wage, working environment, working hours and othergeneral working conditions.
We regularly hold meetings with the "Central Labor-Management Council", the "Divisional
Labor-Management Council", and the Divisional Labor-Management Council.The division
chiefs themselves and union members directly discuss matters closely related to theworkplace and aim to create a workplace in which it is easy to do one's job.
20

TOYODA GOSEI REPORT 2009

Relationship with our Shareholders
By increasing corporate value and proactively disclosing information,
we strive to enable understanding of our company's achievements and ways of thinking.
Highlight of ﬁscal 2008

Participated in IR events for foreign institutional investors
Revealing production plants of Interior and Exterior parts business unit to the mass media and analysts

Social Report

Achievements and rates of return

Suitable information disclosure as an open company

We regard a reasonable rate of return as a management priority to provide

At our company, through regular information dissemination through our

to our shareholders, and we aim to achieve more dynamic businesshomepage and IR tools as well as the promotion of ﬁnancial brieﬁng and IR

operations, and increase corporate value.

events, we strive for suitable information disclosure.

We proactively developed new products and worked to expand sales in

Twice every year we hold large meetings targeting institutional investors

ﬁscal 2008, but due to the impact of the across the board reductions inand securities analysts, proactively respond to small meetings (individualautomobile productions domestically and overseas the automotive parts

discussions) as well. Also, we participated in IR events for foreign

operations that are our mainstay had sales of 546.3 billion yen, down 17.5%

institutional investors in ﬁscal 2008.

from the previous year.
With respect to proﬁts in the new market of the optoelectronic productsthat represent our non-automotive parts business, we were able to secure
an increase in proﬁts by the price reduction eﬀorts such as the eﬀects ofincreased sales and yield ration improvement. As for automotive parts
business, regardless of conducting exhaustive streamlining eﬀorts, we wereunable to absorb the negative impact of decreased production, and our■ Main IR Activities
Targeted person
Domestic institutional investors
Securities Analysts
Overseas institutional investors
Individual shareholders
and investors

IR activities
Financial brieﬁng, Individual consultation
Plant tour
Published "Annual Report"
Participation in IR events
Published "Report on Achievements"
Dissemination of ﬁnancial and IR information by the homepage

ordinary income of 12.1 billion yen represented a decrease of 75.9% incomparison with the previous year. Our net income
for the period was 3.9 billion yen, down 87.2%
from the previous year. As a result, annual dividend
payouts were set to 36 yen per share.
Report on Achievements■ Changes in Dividends

Appeal to activism and thinking
through plant tours

(yen)

60

46.0

16.0

18.0

19.0

'03

'04

'05

30peopleanalysts.

26.0

In ﬁscal 2008 we held a plant tour at the Seto Plant and publically revealed
our production systems of interior and exterior parts business unit for the

0

'02

'06

'07

'08 (Fiscal year)

Financial institutions

31 March,
2009

31.5

31 March,
2008

31.7

0

Foreign investors

40

Treasury stocks
0.5

49.1

11.9

49.0

13.0 5.6

0.2
20

these have become precious opportunities to convey our company's

Japanese companies etc. Individuals and others

Financial products traders
0.1

ﬁrst time. After the tour we held a colloquium, establishing a place tocommunicate with top management including our Chairman and President;■ Distribution of Shareholders

philosophy and stance.

6.9

0.5
60

80

100 (%)
Mass media and analyst plant tours

21

Participantsin plant tour

At our company we conduct plant tours for mass media and securities

36.0
30

13.0

Participation in IR events

Our company has strong cooperative ties with suppliers
and look to develop and grow together.
Highlight of ﬁscal 2008

With respect to the labor management of suppliers, we conduct seminars, self-checking,and onsite conﬁrmation and continuosly promote compliance
Proactive responses to discussion pertaining to supplier transactions

PolicyOur basic procurement policy is to "establish a procurement platform beneﬁcial to us and carry out optimum global procurement bypresenting relevant oﬃces and suppliers with procurement plans, policies, etc. that aptly reﬂect the changing procurement conditions
as well as the attitudes of customers and competitors, so that we will be able to produce competitive products." Also, based on the ideathat "suppliers support our company", through the principles of "Genchi", "Genbutsu", and "Genjitsu", we will put our company to workand develop supplier structural strengthening policies.

Holding a procurement policy
explanation session

Participant company
in the procurement
policy explanations session

200companies

Social Report

Basic Procurement

TOYODA GOSEI REPORT 2009

Relationship with our Suppliers

conducted seminars, self-checking, and onsite conﬁrmation to promotecompliance even further.
Also, with respect to the worsening of economic conditions, we are

We hold a procurement policy explanation session every April to indicate

proactively moving forward discussions with suppliers concerning

the direction we should go toward creating the atmosphere that surrounds

management and responding to transaction problems.

our company and have our procurement policy for the year ﬁrmly
understood.

Strengthening our collaboration with suppliers

We ask approx. 200 suppliers of products parts, processing, materials,
facilities, and metal molds to participate in this session to discuss "ourFour times each year, about 100 suppliers participate in a procurement

challenges and actions to be taken" and, in relation to this year’s

liaison meeting. The content of this meeting includes expansion of"procurement policy", to talk about safety, quality, quantities, costs,

production information, quality control, compliance activities, safety

technology, global expansion, CSR, etc. so we can enhance the level ofactivities, earthquake countermeasures, security management, harmful

coordination with these suppliers.

substances management, etc. We plan to enrich the content by,

We also give awards to suppliers who have provided a noteworthy

incorporating ongoing themes and introducing new themes such as public

contribution in each ﬁeld, showing our appreciation in order to encourage

guarantees, lending, subsidies and lateral development regarding

all the suppliers who participated to continue progress. This time, inrecommended ways to handle reduced production.

addition to past awards given in the ﬁelds of quality, price, and technology,
we also established an "Environmental Contributions Prize".

Promoting green procurement
Based on our company's "Green Procurement Guidelines (2nd Edition)" we
continue to expand environmental activities. The structure of the guidelines
is divided into 2 components: "environmental management" and "harmful
substances management".
We have produced good results in "environmental management" by

Procurement policy briefing session

acquiring ISO14001 certiﬁcation involving, energy saving and waste
reduction.

Tackling quality improvement, complianceIn addition to continuing to respond to the EU's ELV*1 regulation, we arealso conducting components conﬁrmation in response to the EU’s REACH*2

We are taking actions to grow with our suppliers through standardized work

regulation. As a new theme we would like to unite with suppliers to move

maintenance,prevention of defective outﬂow for quality improvement, andforward with VOC*3 management in "harmful substances management".

the suppliers’ participation regarding the design of metal molds andproducts and through cost reduction activities geared toward improving*1 End of Life Vehicle*2 Registration, Evaluation, Authorisation and Restriction of Chemicals*3 Volatile Organic Compounds

competitiveness.
With respect to the labor management of each company in ﬁscal 2008, we
22TOYODA GOSEI REPORT 2009

Involvement in Local Communities
As regional good corporate citizens we are trying to have a positive presencein our local communities.
Highlight of ﬁscal 2008

Establishment of volunteer centers as volunteer activities sites
Making active eﬀorts to handle overseas sites volunteer activities
Participatedin the cleanups

Social Report

Further bolstering social contribution activities

Thorough cleanup activities at each plant Over1,000

As an automotive parts manufactures, we are making eﬀorts to create a

On "Zero Waste Day", held on May 30 every year, our main plants holdbetter local communities though interaction with local residents, such as

cleaning activities in their communities in response to campaigns tohaving traﬃc safety educational activities, fostering the development ofeliminate illegal dumping, and beautiﬁcation campaigns, arranged by local

youths, and supporting the socially vulnerable. As a global corporation, wegovernments.

put emphasis on this country’s socialization and regionalization and we are

In ﬁscal 2008 it was estimated that over 1000 employees participated inpositively working on volunteer activities in regions where our overseas

cleanup around our plants. We also are promoting local beautiﬁcationsites are located.

campaigns like neighboring cleanup activities at 9 plants including theWe established volunteer centers in the general administration division toHaruhi Plant.

employees in total

bolster our contribution activities further in ﬁscal 2008. These centers have apositive presence in our local communities. provide organizational support
such as the enhancement of current activities,plans for new activities andcollecting and disseminating information while collaborating with local
communities.
Zero waste cleaning activities

Proactive volunteer activities at overseas sites

Participated in the
traffic safety campaign

Emphasising the importance of traﬃc safety 3,000employees
in total

23

We are conducting volunteer activities appropriate to each region or country

We are focusing our eﬀorts on regional traﬃc safety educational activities toat our overseas sites. Their content has been diversiﬁed to include

reduce traﬃc accidents and protect vulnerable road users, in collaboration

contribution of education, welfare and local events, education/sports

with local governments and the police. About 3,000 employees participate inassistance, local cleanup activities, and philanthropy. Also, during times of

the traﬃc safety campaigns held each season during periods designated as

disasters we provide moneys in token of sympathy for victims and"Toyota Group Traﬃc Safety Month". In addition to advocating traﬃc safety

donations. Employees actively participate in volunteer activities at eachat intersections near our plants, in February of ﬁscal 2008 we conducted theplant and contribute to local communities while familiarizing themselves

23rd "Traﬃc Safety presentation(on Valentine’s Day)" and informed

with local residents.

kindergarten students of the importance of traﬃc safety.

Stationary Donation for local elementary school (TGKL)

Traffic Safety presentation at kindergarten

TOYODA GOSEI REPORT 2009

Participantsin the club

73people

Club team players held sports
classrooms in each region

Total classes ofholding three clubs

100

Social Report

Fully supporting "Ichinomiya Boysand Girls Invention Club"

More thantimes

The "Ichinomiya Boys and Girls Invention Club" was launched in 2007; its goal

Our company is concentrating on the promotion of company sports; weis to provide a setting that will nurture the dreams and passion for inventions

have a volleyball team named "Trefuerza" in the V-Premier League, aand technology of young boys and girls leading the next generation. Throughhandball team, the "Blue Falcon", in the Japanese League, and a basketball

the experience of creating something, we hope to help them grow into creative

team, the "Scorpions", in the Japanese League Division 2.

human beings. Our company has fully supported the club after its creation, andEach club held classes in their spare time before their league match start

we are participating in its planning and management, providing educationaland during their oﬀ season in the neighboring communities, emphasizing

materials and facilities, and dispatching retired employees to act as leaders.

on local interchange through sports.

In addition to the 25 participants from the previous year, 48 new students

In ﬁscal 2008 the blue Falcons and Scorpions were widely involved in suchparticipated in ﬁscal 2008, and they conducted activities such as making arts

activities as interacting with disabled people.

and crafts using everyday materials, making crafts with wood, and freecreation of things using ourcompany's LED.
We will provide ourfacilities as the classroom
in ﬁscal 2009.

Volleyball class

Handball class

Ichinomiya Boys and Girls Invention Club

http://www.toyoda-gosei.co.jp/kigyou/sports/index.html"Wheelchair doctors" visiting
welfare facilities and hospitals

The number of annual
repairing wheelchairs
Approx.

240

Our company’s employee volunteer group the "Wheelchair Doctors" visit sixof the nursery homes and hospitals within Inazawa City once a month andDonating soccer tickets to the facilities
for disabled people

repair wheelchairs. These activities have continued for 12 years; a volunteer
group of about 10 wheelchair doctors adjust and repair loose brakes, broken

We donated tickets for the Nagoya Grampus home game to vocational aid

foot pedals etc.

centers for disabled people at "Kashinoki Sagyosyo" and "Sobue Walfare

Due to a request from a local high school, in ﬁscal 2008 we visited theHouse" so that disabled people who have few opportunities to go out could

school for the ﬁrst time and provided wheelchair repair technical instruction

enjoy a soccer match.

to students.

Wheelchair doctors

Everyone from "Kashinoki Sagyosho" who watched the soccer match

24

TOYODA GOSEI REPORT 2009

Globally Expanding Environmental Management
In order to appropriately respond to environmental problems that have spread to a global scale, we
are further promoting environmental activities that include the domestic and overseas aﬃliatedcompanies.
Based on our environmental policy, we are conducting numerous activities with the environment in mind.
In addition to taking the environment into consideration in every process from development through production and sales,
we quickly respond to changes in the law and the needs of our time and are tackling environmental activities as Toyoda
Gosei Group.

Environmental Report

Environmental Policy
１ Promotion of environmentally-friendly
corporate activities
Maintain the awareness that our business is
deeply linked to the environment at every stage
from development, production, and sales todisposal. Promote environmentally-friendly
corporate activities in cooperation withcustomers and public administrations as the
Toyoda Gosei Group, including the domestic
and overseas aﬃliated companies and suppliers,
as well as all the business units of Toyoda Gosei.
２ Eﬀorts as a good corporate citizen
Take a progressive approach to local and social
environmental activities as a good corporate
citizen while participating in and oﬀering
support and cooperation for environmental
activities with various organizations. Educate
our employees so that they participate inenvironmental activities as a member of theregion or community, while oﬀering them
support for their social contribution andvolunteer activities.
３ Transmit the information of these eﬀorts
broadly and listen to a variety of opinions for
greater improvement of activities.

Organization for Promoting Environmental Action

Meet the challenge ofhigher goals

Zero Cases of Non-complianceand Complaints˝ Activities
Response to Europe’s REACH*1 regulations
Establishing the SOC management foroverseas major sites including China

Developing Global EMS
Total elimination of hexavalent chromium
use in products

2005
Formulation of the fourth
Environmental Action Plan

8% reduction in CO2 emissions per sales unit
compared to fiscal '03 (consolidated)
5% reduction in materials discarded per sales
unit compared to fiscal '03 (consolidated)
Continuing our policy of zero landfill waste
and zero incinerated materials

Reduction in the emission of VOC*2 and PRTR*3 substances
Compliance Management

Establishment
Cutting overall CO2 emissions toEnvironmentally friendly
5% below the fiscal 1990 level
manufacturing
Expanding material recycling
Zero landfill waste

1991
Set up "Nicely"
Committee

The Toyoda Gosei group's acquisitionof ISO 14001 certification

2000
Formulation of the third
Environmental Action Plan

Main domestic plants acquired ISO 14001
Environmental accounting
Strengthened environmental education
75% reduction in waste (compared to fiscal 1991)
Total elimination of chlorinated solvents

Total elimination ofchlorofluorocarbons (CFC)"Nicely"("nai"-three) to People and the Earth

1993
Formulation of the first
Environmental Action Plan

1996
Formulation of the second
Environmental Action Plan
Strengthened environmental management system
50% reduction in waste (compared to fiscal 1991)
Total elimination of CFC substitutes and trichloroethane■ Diagram of the Organization for Promoting Environmental Action
Product area Product and Technology Environment Subcommittee

The "Environmental Committee", with our President as chairman, discusses
Gosei Group as a whole. Our Environmental Committee is made up of 3
and management activities from their own professional viewpoints incooperation with subsidiary organizations such as liaison committees andworking groups.
*1 Registration, Evaluation, Authorisation and Restriction of Chemicals*2 Volatile Organic Compounds*3 Pollutant Release and Transfer Register*4 Substances of Concern (Environmentally harmful substances)Environmental Committee

subcommittees; these subcommittees promote environmental conservation

Chairperson: company president

and determines important issues of environmental policies for the Toyoda[Promotes and manages development of environmentallyfriendly products and technologies]

Manufacturing
area

Production Environment Subcommittee[Promotes and manages measures and technologies thathave zero emissions during manufacturing processes]
Liaison Committee for Environmental Communication with
Domestic Aﬃliated Companies[Manages, guides, and supports consolidated eﬀorts for environmental
conservation among aﬃliated companies and major suppliers in Japan]
Liaison Committee for Environmental Communication with
Overseas Aﬃliated Companies[Manages, guides, and supports consolidated environmental
conservation eﬀorts among overseas aﬃliated companies]

Quality Assurance
Subcommittee on Systems for SOC*4 Regulations and Quality Assurancearea[Develops systems to address SOC*4 regulations and quality control]
The environmental committee and subcommittees send information toplants and other worksites through specialized committees establishedaccording to their own ISO 14001 systems.

25

These are the results of the Fourth Environmental Action Plan (ﬁscal 2006 to 2010) and results of theactivities for ﬁscal 2008.
We have set more challenging objectives and are continuing those activities which we have alreadyachieved their goals.

Reference
page

Results of the Activities in Fiscal 2008

① Development of products and technologies which contribute to ﬁrst-rate
fuel consumption
Development of products and technologies for weight reduction

Examples of development in weight reduction ・・・・・・・・・・・・・・・・・・・・・
̶ Developed a fuel inlet pipe made of Plastic

Development/Design

Environmental Report

Implementation

Theme

TOYODA GOSEI REPORT 2009

Fourth Environmental Action Plan

P28

Development of products and technologies with lower power consumption
Development of products and technologies for improving aerodynamics② Development of built-in parts for clean energy vehicles and their eﬀective
introduction/ popularization
Development of products and technologies for fuel-cell vehicles

Development of products and technologies for vehicles
Materials compatible with new fuels④ Reduction of CO2 in production and Logistics activities

Production/Logistics

Energy saving/prevention of global warming③ Development of technologies for various energy sources and fuels

Production case studies
̶ Independently developed a molding machine・・・・・・・・・・・・・・・・・・・・
Eﬀorts for logistics・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Improved eﬃciency of loading̶ Localization of productions among customers
̶ Focused extensively on fuel-eﬃcient driving

Item
Consolidated CO2 emissions per sales unit
Production

Nonconsolidated
Nonconsolidated［1］

Logistics(Non-consolidated)

CO2 emissions
CO2 emissions per sales unit
CO2 emissions
CO2 emissions per sales unit

Goals for Fiscal 2010
Reduce by 8% compared toﬁscal 2003
Reduce by 10% compared toﬁscal 2003
Reduce by 15% compared toﬁscal 2003
Reduce by 10% compared toﬁscal 2003
Reduce by 10% compared toﬁscal 2003

P28
P29

Evaluation［3］Results for Fiscal 2008
90

Achieved a 10% reduction
compared to ﬁscal 2003○

P28

117,000 tons of CO2

Achieved a 5% reduction comparedto ﬁscal 2003
(Increased by 1% compared to ﬁscal 1990)

○

P28

○

P28

○

P29

○

P29

［2］

86［2］
12,816 tons of CO2
88［2］Achieved a 14% reduction
compared to ﬁscal 2003
Achieved a 4% reduction
compared to ﬁscal 2003
Achieved a 12% reduction
compared to ﬁscal 2003

［1］Applicability: Delivery, mid-process, and procurement logistics［2］This value takes the ﬁgure in the base year as 100. ［3］○：Goal for ﬁscal year was achieved, ×：Goal for ﬁscal year was not achieved.

Development/Design⑤ Development of recycling technologies
Development of technologies for improving ELV*parts recycling⑥ Further promotion of designs which facilitate recycling
Further promotion of designs which facilitate recycling and theirapplication to products

Production/Logistics

Recycling of resources⑦ Further promotion of eﬀective utilization of resources for realizing therecycling society

ItemEﬀorts for enhancing recycling eﬃciency・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Promoting new recycling techniques̶ Responded to regulations of laws, such as the European Union's(EU) ELV* Directives and to the ELV Recycling Law*End of Life Vehicle

Production case studies・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Waste rubber reduction through desulphurization technology

P30

Eﬀorts for logistics・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Reduction of packaging materials

P30

Goals for Fiscal 2010

Evaluation［4］Results for Fiscal 2008

ConsoliMaterials dated Volume of waste per sales unit
Discarded Non- Volume of waste per sales unit
consolidated

Reduce by 5% compared toﬁscal 2003
Reduce by 5% compared toﬁscal 2003

77

Landﬁll waste
Waste(Non-consolidated) Incinerated waste

Maintain zero emissions

0t

Zero emissions

15t［3］

Packaging materials Volume of use
Logistics［1］ (Non-consoli-dated)
Volume used per sales unit

Reduce by 10% compared toﬁscal 2003
Reduce by 15% compared toﬁscal 2003

109t

Production

P29

［2］

77［2］

33［2］

Achieved a 23% reduction
compared to ﬁscal 2003
Achieved a 23% reduction
compared to ﬁscal 2003

̶Achieved a 99% reduction
compared to ﬁscal 1998
Achieved a 54% reduction
compared to ﬁscal 2003
Achieved a 67% reduction
compared to ﬁscal 2003

○

P30

○

P30

○

P30

○

P30

○

P30

○

P30

［1］Applicability: Delivery, mid-process, and procurement logistics ［2］This value takes the ﬁgure for the base year as 100. ［3］This ﬁgure is converted into an annual value at the end of the ﬁscal year.
［4］○：Goal for ﬁscal year was achieved, ×：Goal for ﬁscal year was not achieved.

26

Environmental Report

Theme
Development/Design/
Mass production

TOYODA GOSEI REPORT 2009

Fourth Environmental Action Plan

Implementation⑧ Management of environmentally harmful substances Further promotionof reduction activities Total elimination worldwide of 4 environmentally
harmful substances*1 subject to restriction

Production/Logistics

Environmentally hermful Substances⑨ Reduction of emissions of PRTR*2 substances

Item
Emissions of PRTR substances

Goals for Fiscal 2010
Reduce by 55% compared to ﬁscal 2000

Results of the Activities in Fiscal 2008
Promoted managerial and reduction activities ・・・・・・・・・・・・・・・・・・・・・

P31

Examples of development leading to the reduction ofEnvironmentally harmful substances ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Paint-free for air puriﬁer front plate

P31

Reduced PRTR*2 substances ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Improvement of paint coating eﬃciency

246t

P32

Evaluation［1］Results for Fiscal 2008
Reduce by 61% compared to ﬁscal 2000○

［1］○：Goal for ﬁscal year was achieved, ×：Goal for ﬁscal year was not achieved.

⑩ Reduction of VOC*3 emissions

Reduction of VOC*3 emissions・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Water based paint for instrument panels
̶ Recovering washer thinners

Item
VOC emissions per sales unit

Goals for Fiscal 2010
Reduce by 50% compared to ﬁscal 2000

［1］This value takes the ﬁgure in the base year as 100.

42［1］

P32

Results for Fiscal 2008
Evaluation［2］Reduce by 58% compared to ﬁscal 2000○

［2］○：Goal for ﬁscal year was achieved, ×：Goal for ﬁscal year was not achieved.

⑪ Further CO2 reductions from global business activities

Understood the actual reduction in global CO2 emissions
and promoted the established reduction plan ・・・・・・・・・・・・・・・・・・・・・・⑫ Enhancement of consolidated environmental management

Enhancement of consolidated environmental management
̶ Domestic and overseas plants acquired ISO14001 andthe current assessment status ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Environmental Audits (Internal Environmental Auditing,External Environmental Auditing) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ (Kaiyo Gomu Co.,Ltd.) – Eﬀorts of the domestic aﬃliated companies・・・・
̶ (TG Kirloskar Automotive) – Eﬀorts of overseas aﬃliated companies ・・・・

P32

P32
P33
P34
P34

Management
Environmental management
Cooperation with society⑬ Further promotion of environmental management by business partners

Promoted Procurement Policy̶ Held seminars regarding Procurement Policy・・・・・・・・・・・・・・・・・・・・・・
̶ Contained survey of very high concern substances covered・・・・・・
by the EU’s chemical substances regulation REACH*4

P22
P31

⑭ Enhancement of environmental education

Systematically implemented environmental education programs・・・・・・

P33⑮ Promotion of new business activities which contribute to improving theenvironment

Examples of promotion of new business activities which ・・・・・・・・・・
contribute to improving the environment
̶ Expansion of LED business for consumer use

P35⑯ Steady reduction of environmental burden in life cycle through full-scale
application and popularization of Eco-VAS.*5

Regularly reported data on resource consumption andenvironmental impact based on clients' systems

̶⑰ Contribution to formation of a recycle oriented society

Community case studies
̶ Cooperated in community cleaning activities ・・・・・・・・・・・・・・・・・・・・・
̶ Proactive volunteer activities at overseas sites・・・・・・・・・・・・・・・・・・・・・
̶ Begin aﬀorestation at plant sites ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

P23
P23
P36

⑱ Disclosure of environmental information and enhancement of interactive
communication

Disclosure of environmental information and enhancement ofinteractive communication・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・
̶ Holding a plant tour for the mass communication and analysts(Seto Plant)̶ Participation in Messe Nagoya 2008
̶ Publication of "Toyoda Gosei Report 2009"⑲ Proactively contributing to and advising on environmental policies witha view to sustainable development

Participated in the environmental policies of the Japan Auto
Parts Industries Association, the Japan Rubber Manufacturers
Association and other organizations*1 Lead, mercury, cadmium, and hexavalent chromium *2 Pollutant Release and TransferRegister *3 Volatile Organic Compounds*4 Registration, Evaluation, Authorisation and Restriction of Chemicals *5 Eco-Vehicle Assessment System

27

Reference
page

P21

̶

We have bolstered our handling of vehicle weight reduction and energy diversiﬁcation. While planninghigh productivity and logistics streamlining, we aim to reduce CO2 emissions.
Highlight of ﬁscal 2008

Nonconsolidated: We achieved reducing CO2 emissions by 5% toward the goal of a 10% reduction from ﬁscal 2003 toﬁscal 2010. We also achieved the goal of CO2 emissions per sales unit (a 14% reduction compared to the goal of 15%)

Consolidated: We achieved a 10% reduction in CO2 emissions per sales unit,
surpassing our goal of an 8% reduction.
Development/Design

Handling vehicle weight reduction andclean energy

TOYODA GOSEI REPORT 2009

Energy Saving/Prevention of Global Warming

Under the "Fourth Environmental Action Plan", we developed the following

Realization of weight reduction through a switchover
to resinmatters of clean energy vehicles and fuel diversiﬁcation.

We changed conventional steel fuel inlet pipes through which thefuel tank is supplied with fuel from the ﬁll opening to resin andsucceeded in a 50% weight reduction. By using polyethylene and
EVOH* in our materials, we plan to improve durability and fuelpermeation prevention.

Based on this, in ﬁscal 2008 we contributed to vehicle weight reduction*Ethylene vinyl alcohol copolymer

detailed implementation issues for product development: ① vehicle
weight reduction that aims to improve fuel eﬃciency; ② responding to theEnvironmental Report

Case study

through such means as changing over to plastic fuel inlet pipes.

Refueling-side

Production

Energy saving equipment introduction andCO2 emissions reduction

Tank-side
Plastic fuel inlet pipes

As part of Toyoda Gosei Group's global warming prevention policy, we strove
to reduce energy consumption while improving productivity. Since ﬁscal
2005 we have made it our goal to have energy reduction of more than 30%
in our new facilities of a certain ﬁxed scale, and through the present weCase study

have been replacing equipment with low-energy versions.

Reducing energy loss through independently
developed molding machines■ Changes of CO2 Emissions per sales unit (index)
Consolidated

Nonconsolidated

CO2 emissions per sales unit (index)

Consolidated
Goal

100

8%

reductioncompared toﬁscal 2003

90
86

Nonconsolidated
Goal

80
0

15%

'03

(the base year)

'04

'05

'06

'07

'08

reductioncompared toﬁscal 2003

'10

(Fiscal year)

As a joint venture between the Equipment Division and Molding
Division, we independently developed molding machines andreduced energy loss stemming from manufacturing of products.
By proactively reducing mold clamping loss and conveyance loss
that had occurred with our conventional molding machines(commercial devices) and making the molding machines
themselves more compact, we cut energy waste.
Through this we succeeded in reducing consumed energy by 15%
in comparison with conventionally commercial molding machines(electric motor).
Comparison of energy consumption for molding
Energy consumption(kWh)*CO2 Emissions per sales unit (index) takes the ﬁgure for CO2 emissions in ﬁscal 2004 as 100

Idling loss

■ Changes in CO2 Emissions
Goal

11.7

10%

reductioncompared toﬁscal 2003

'03

(the base year)

'04

'05

'06

'07

'08

'10

(Fiscal year)* For the CO2 conversion factor, the following ﬁgures are used:
Conversion formula: [kg-CO2]=［kg-C］×3.67 Electricity: 0.3817kg-CO2/kWh
Heavy oil A: 2.7kg-CO2/L LPG：3.0094kg-CO2/kg City gas: 2.3576kg-CO2/m3
Kerosene: 2.5308kg-CO2/L）

Hydraulicminiaturization
Mold clamping
optimization

Conveyance Necessary
lossenergy0（

by approx.5%
compared toﬁscal 1990

15％ reduction

Heatreleaseloss

7

Overspecification

12.3

Energy loss

CO2 emissions (10,000t-CO2)

14

Until the present Until the present(hydraulics)(electric motors)

Compactification

Development(reference)

28

TOYODA GOSEI REPORT 2009

Energy Saving/Prevention of Global Warming

Logistics

Environmental Report

Thorough logistics in response to quantity
ﬂuctuations■ Three Pillars for Activities Designed to Reduce CO2Emissions from Logistics Operation
1. Actions to increase eﬃciency and to reduce the numberof vehicles dispatched

To reduce CO2 emissions during transportation, we streamlined cargo,dispatching appropriate production quantities, and determining loading

2. Shortening ﬂow line through route alterations andlocalization of production sites

capacity based on the "3 Gen-ism" ("Genchi", "Genbutsu", and "Genjitsu",

3. Pursuing transportations producing less CO2 emissions

which are translated as "actual locations", "actual materials" and "actual
situations", respectively) and tried to "improving eﬃciency of loading" Every
year we set challenging goals and move forward.

Goal

10%

reductioncompared toﬁscal 2003

100

20,00012,81688

13,403
10,0000

80'03(the base year)

'04

'05

'06

'07

'08

'10

0

Emissions per sales unit (index)

among customers" as a "shortening of logistics ﬂow lines".

Emissions (in tons of CO2)

Also we reduced CO2 emissions by expanding "Localization of productions■ Changes in CO2 Emissions and in Emissions
per sales unit (Index)(Fiscal year)*CO2 Emissions per sales unit (Index) takes the ﬁgure for CO2 emissions in ﬁscal '03 as 100.
*Applicability: Delivery and mid-process logistics

Resource Circulation
Through eﬀective resource utilization and recycling of goods,
we pursue production activities without material discarded.
Highlight of ﬁscal 2008

Nonconsolidated: We achieved reducing materials discarded by 13% compared with ﬁscal 2003
Consolidated: We achieved a 23% reduction in materials discarded per sales unit versus a goal of 5%
from ﬁscal 2003 to ﬁscal 2010.
Development/Design

Promoting new recycling techniques■ Technological Development for ELV Parts Recycling
Key items

Our company promotes design that keeps recycling in mind, and in ﬁscal
2008 we focused our eﬀorts on high quality material recycling technology

New recycling

Approaches
・New recycling techniques(high quality material recycling)・Techniques to separate composite materials

to promote reuse of high polymer materials such as rubber products.
We are accumulating technology that enables mid process recycling
technology to be used in ELV* parts recycling.

Installing parts made ofrecycled materials in vehicles

Designing products that areeasy to recycle*End of Life Vehicle

29

・Development of applications for recycledmaterials
・ELV parts recycling technology
・Easy-to-recycle materials, and innovative
component units
・Easy-to-dismantle designs for products

TOYODA GOSEI REPORT 2009

Production

To handle resource circulation in the production stage, we are moving■ Amount of Waste Generated / Waste Disposal Situation(Results for Fiscal 2008)

Numbers inside < > are proportions of the emissions.

Amount ofinternal reusing
3,126tAmount of valuable resource 6,168t〈36.9%〉

forward with 3 reduction activities: those of "landﬁll waste", "incinerated
Amount ofmaterials
discarded
16,722t〈100%〉

waste", and "material discarded".
We are making great improvements with respect to materials discarded,

Amount ofincinerated waste
15t
Amount of landﬁll waste 0t 〈0.1%〉〈0%〉expanding in-house re-making pellets of resin.
*Ethylene propylene rubber

Receiving the GSC prize for desulphurization

20,000By extensively readjusting the necessary disposable packaging materials usedin reusable shipping cartons, in ﬁscal 2008 we achieved our diﬃcult goal ofand by maintaining the washed and clean state of returned shipping cartons
we strove to eliminate the necessity of laying dirt-blocking paper on the

'06

）

'08

'07

(Fiscal year)

Nonconsolidated

Goal

5%

reductioncompared toﬁscal 2003

80
0

77
'03

'04

(the base year)

'05

'07

'06

'08

'10

(Fiscal year)*Materials discarded per sales unit (Index) takes the ﬁgure for materials discarded in ﬁscal 2003 as 100.

■ Changes in Amount of Incinerated Waste
1600
400

330

200

0

15
'98

(the base year)

'03

'04

'05

'06

'07

'08

16 or less

Goal

99%

reduction'10 compared to(Fiscal year) ﬁscal 1998

*Figures are converted into annual values at the end of the ﬁscal year.

■ Changes in Use of Product Packaging
Materials and Usage per sales unit
(index)

100

Goal

10%

235

reductioncompared toﬁscal 2003

150

0

Goal

15%

reductioncompared toﬁscal 2003

50

109
33
'03

(the base year)

'04

'05

'06

'07

'08

'10

0

Usage per Sales Unit (index)

300
Usage (tons)

targeting "Zero" disposable packaging materials as our ultimate goal.

'05

100

customers and reducing lead times, we diminished the number of tumblers.
promote this eﬀort by setting up challenging targets every year while'04

Consolidated

bottoms of cartons. Also, by advancing localization of production among
This also led to a reduction in packaging materials. We will continue to'03

10% reduction
compared toﬁscal 2003

■ Changes in Amount of Materials Discarded per sales unit (index)

109t, which makes a 15% reduction compared to the previous ﬁscal year.
Furthermore, we thoroughly improved the storage state of shipping cartons,

0(the base year)

Amount of incinerated waste(in tons)

Reduction of packaging materials through shipping
carton storage/management and local production（

15,000*Green Sustainable Chemistry

Logistics

19,20016,722

Materials Discarded per
sales unit (index)

At our company we developed technology to recycle the EPDM
rubber products that had heretofore been problematic in terms ofreuse and resource conversion into high quality recycled rubber.
Through this we are reusing mid-production process wastematerials and recycling them into raw materials for the same sort ofproducts.
Our technical development and mass
production achievements were
evaluated, and in 2008 we received
the GSC* prize from the Green &Sustainable Chemistry Network, Japanin which the Ministry of Economy,
Trade and Industry (Observer)
participates that centers on Japan
Chemical Innovation Institute.

■ Changes in Amount of Materials Discarded
Materials discarded (in tons)

Case study

Amount ofmaterial recycled
8,570t〈51.2%〉
Amount ofthermal recycled
8,137t〈48.7%〉

Amount of waste
10,539t〈63.0%〉

reductions by desulphurization of graft hair aﬃxed EPDM* rubber andEnvironmental Report

Reducing Waste and Materials Discarded(Fiscal year)*Usage per sales unit (index) shown takes the ﬁgure from ﬁscal 2003 as 100.
*Applicability: Delivery, mid-process, and procurement logistics

30

TOYODA GOSEI REPORT 2009

Environmentally Harmful Substances
In response to the more stringent worldwide regulation for Environmentally Harmful Substances, wehave reduced the substances contained in the products and have established a comprehensive
management system.
Highlights of ﬁscal 2008

Handling of SVHC*1 covered by the EU's chemical substances regulation REACH*2

Development/Design

Environmental Report

Reduction of Environmentally Harmful Substances and our global response
In response to the European Union (EU)'s ELV*3 directives our company has

substances of our enterprises and disclosing information concerning SVHC.

eliminated the use of 4 regulated substances by ELV (lead, cadmium,

To handle this, our company is formalizing a contained survey of SVHC andmercury and hexavalent chromium) by ﬁscal 2007 in advance of the bancountermeasures to inspect our raw materials or indirect materials in ﬁscal

dates. We have domestically and abroad established and maintained a2008.

structure/management system for avoiding the use of Environmentally

In response to the voluntary control of the Japan Automobile Manufacturers

Harmful Substances and conducting exhaustive inspections to ensure that

Association, we are tackling vehicle interior VOC*4 reduction and adopting

these substances are not included in products at each step from productnon-VOC adhesives and water-based paints for interior parts of adhesives as

design to mass production.

we continue with our reexamination of the raw materials we use

Also, starting in 2007 the EU's chemical substances regulations REACH were

throughout our manufacturing processes.

put into eﬀect, and we were given the duty of registering existing chemical■ Eﬀorts to Reduce Environmentally Hazardous Substances
Division

Response
to voluntary
control

Lead compounds

Response
to legal
controls

Key countermeasure substances(Applications)

Situation of countermeasure(Rubber vulcanizing agent)’98 Totally eliminated(PVC stabilizer and lubricant)’01 Totally eliminated(Vulcanizing adhesive)’02 Totally eliminated(Cation electro-coated paint)’04 Totally eliminated(Soldering)

Lead free soldering has been
applied to new parts

Hexavalent chromium’07 Totally eliminated

PVC

Reduced usage

Environmental hormones(endocrine-disrupting chemicals)

Banned use in new products

VOCs in vehicle interiors(Paints and Adhesives)

Responded to clients’voluntary controls

Case study

Showing consideration toward the environment by
not using paintTaking the environment into consideration, we produced "paint-free"
air puriﬁer front panels. Also because it is diﬃcult to recycle painted
plastic products, this will be helpful for the recycling process as well.
Ordinarily non-painted plastic molding
will show the weld lines (surface defects
at welding) resulting in appearance
quality problems. As a result of athorough examination of the smallest
details of the molding process such as
plastic materials quality and metal moldstructure, we succeeded in creating alustrous, beautiful exterior with no weld
line.

Production

Reduction of Environmentally Harmful
Substances in the production process■ Emission/Flow of PRTR substances (Results for Fiscal 2008)(Unit: ton)Gases emitted
into theatmosphere246

We have been reducing Environmentally Harmful Substances such as PRTR*5

Recycling
7.6

and VOC target substances toluene and xylene in the production process. In
ﬁscal 2008 we are promoting the changeover from solvent paints to water
based paints, improving of paint coating eﬃciency, and recovering washingthinners for spray guns.
*1 Substances of Very High Concern*2 Registration, Evaluation, Authorisation and Restriction of Chemicals*3 End of Life Vehicle*4 Volatile Organic Compounds*5 Pollutant Release and Transfer Register31

Amount ofchemical
substances
685

Products
204

Released Released
into
into
water ways sewers
0.14
0.11

Released
into thesoil
0VolumeRemovalmoved as (amountwaste
of disposal)
139
88

TOYODA GOSEI REPORT 2009

■ Changes of VOC Emissions/Emissions per sales unit (Index)
55%

625

reductioncompared toﬁscal 2000

400

246

0

'00

(the base year)

'04

'05

'06

'07

'08

'10

(Fiscal year)

reductioncompared toﬁscal 2000

1,169
669

800

0

Goal

50%

1,600

'00

(the base year)

'04

'05

'06

'07

'08

100

50

42

'10

0

Emissions per sales unit (Index)

Goal

Volume emitted (in tons)

Volume emitted (in tons)

800

Environmental Report■ Changes of PRTR Substances Emitted(Fiscal year)*VOC Emissions per sales unit (index) takes the ﬁgure for VOC emissions in ﬁscal 2000 as 100

Environmental management
We are collaborating with our domestic and overseas aﬃliated companies to promote thoroughenvironmental management and reduced environmental burdens.
Highlight of ﬁscal 2008

Strengthening environmental management systems in the North America region and handling things in a way appropriate to the region
Begin local resident participation-type aﬀorestation at Heiwacho Plant
Management

Enhancing actions at Toyoda Gosei GroupIn regard to our environmental actions, all of Toyoda Gosei Group promotes
environmental management and environmental burden reduction.

■ Subject to Consolidated Eﬀorts for Environmental Conservation●Acquired ISO14001 certiﬁcation
New companies and main plants are encouraged to acquire ISO14001 certiﬁcation within
three years of starting operations

Toyoda Gosei

We have been collecting environmental data from each group company,
starting with domestic aﬃliated companies in ﬁscal 2001 and overseas
aﬃliated companies in ﬁscal 2004, established reduction plan which is baseDomestic
Aﬃliateson it’s environmental data (CO2 emissons, volume of waste) and arepromoting the shared goals of the Toyoda Gosei Group companies for ﬁscal
2010.

Overseas
Aﬃliates● Inazawa Plant● Haruhi Plant● Nishimizoguchi Plant ● Bisai Plant● Kitakyushu Plant● Iwate Plant● Saga Plant● Seto Plant● Morimachi Plant● Heiwacho Plant● Kanagawa Plant● Fukuoka Plant● Ichiei Kogyo Co., Ltd., ● Hinode Gomu Kogyo Co., Ltd.,● Hoshin Gosei Co., Ltd., ● Toyoda Gosei Interior Manufacturering Co., Ltd.
● Kaiyo Gomu Co., Ltd., ● TG Opseed Co., Ltd.
■North America● TG Missouri Corporation● TG Kentucky,LLC● TG Automotive Sealing Kentucky, LLC● TG Fluid Systems USA Corporation● Toyoda Gosei Texas, LLC● TG California Automotive Sealing, Inc.
● TAPEX Mexicana S.A. DE C.V.
● Waterville TG Inc.
● TG Minto Corporation■Asia, Oceania, Europe and Africa● Toyoda Gosei (Thailand) Co., Ltd.
● Toyoda Gosei Rubber (Thailand) Co., Ltd.
● Toyoda Gosei Haiphong Co.,Ltd.
● TG Kirloskar Automotive Pvt. Ltd.
● P. T. Toyoda Gosei Safety Systems Indonesia● Fong Yue Co.,Ltd.
● Tai-yue Rubber Industrial Co.,Ltd.
● Bridgestone TG Australia (Pty) Ltd.
● Tianjin Toyoda Gosei Co., Ltd.
● Tianjin Star Light Rubber and Plastic Co., Ltd.
● Toyoda Gosei (Zhangjiagang) Co.,Ltd.
● Toyoda Gosei (Zhangjiagang) Plastic Parts Co.,Ltd.
● Toyoda Gosei (Foshan) Rubber Parts Co., Ltd.
● Toyoda Gosei (Foshan) Auto Parts Co., Ltd.
● Fuzhou Fu-Yue Rubber & Plastic Industrial Co., Ltd.
● Toyoda Gosei (Tianjin) Precise Plastic Co., Ltd.
● Toyoda Gosei UK Ltd.
● Toyoda Gosei Czech, s.r.o.
● Toyoda Gosei South Africa (Pty) Ltd.

32

TOYODA GOSEI REPORT 2009

Environmental management

Management

Environmental Report

Implementation of Environmental Audits

Indicated byour external
auditing

0case

Our company has put together an auditing team that is working on internal
environment auditing, and it consists of members who are not subject toour plants and oﬃces. Additionally, at Toyoda Gosei Group commissioned
the Japan Quality Assurance Organization (JQA), an external assessment
and registration organization, to conﬁrm whether our environmental
management systems are being run properly in accordance with theISO14001 (revised 2004 version).
In ﬁscal 2008 no speciﬁc problems were found at Toyoda Gosei.
There was one suggestion concerning our domestic aﬃliates but we havealready taken corrective actions on it.

Management

Promoting environmental education at Toyoda Gosei GroupWe are providing suitable education for Toyoda Gosei Group employees
concerning the environmental problems such as the destruction of our
natural environment, environmental contamination, the impact of
production on the environment and observance of environmental laws.
■ Environmental Education System of the Toyoda Gosei Group
Targeted
personToyoda Gosei

Affiliated Companies
Domestic
Overseas

Education for new managers
Education for workers stationed abroad

Company-widecommonness

Education for environmental key-men
Environmental related qualiﬁcations acquisition
Education for new employees
Educational activities for environmentally-focused months
Education for environmental staﬀs
Education to upgrade internal auditors

In relation of
ISO14001

Education to register internal auditors
Education for supervising managers
Education for workers in environmental signiﬁcant work
Education for general workers

Morimachi Plant, External Environmental Auditing

Management

Establishment of environmental management
system at overseas aﬃliated company

Variety of activities for environmentallyfocused months

To unify domestic and foreign environmental management levels, we are
implementing "Global EMS (Environmental Management Systems)".
In ﬁscal 2008 we strengthened North American environmental
management systems, and set an example for our USA, Canada, and Mexico
companies to follow.
With TGNA* as an integrated company, we are implementing regional
company enhancement, information sharing, compliance management,
and local auditing along with establishing a Environmental Committee ofNorth America and tackling action in a manner consistent with theidiosyncrasies of the region.

In observation of Environmentally Focused Month, we are conducting law
observance inspections onsite, putting up posters, and backyard tours byenvironmental managers of such places as CHUBU CENTRAIR International
Airport waste disposal grounds. We also heightened environmental
awareness by having environmental managers take the ECO Test
(Certiﬁcation Test For Environmental Specialists).
Also for the sake of thorough compliance, we are taking action toward "ZeroCases of Non-compliance and Complaints" activities, and thoroughly spot
checking and conducting management.

*Toyoda Gosei North America Corporation

Environmental Committee of North America

33

Eco TestCertiﬁcation

Management

Backyard Tours at CHUBU CENTRAIR International Airport

14people

TOYODA GOSEI REPORT 2009Management

Environmental Report

Eﬀorts of the Domestic and Overseas Aﬃliated Companies
Kaiyo Gomu Co., Ltd.
Proactive environmental burden reduction activities
Kaiyo Gomu, manufacturers of rubber products for use with automobiles, is located in
the Oodai Mountain range and Kumanokodo, a place that brings to mind the depth of
the nature. We are strongly promoting them as an example of energy saving andmanagement of reducing discarded materials. As an energy countermeasure and,because it is an area not yet supplied by municipal gasworks, we are independently
installing an LNG tank base and changing the boiler over to gas. Regarding energy
reuse, we are collecting high temperature wastewater from steam pans and using it toclean rubber. As part of our heat insulation countermeasures, we applied insulation
paint to steam pans. The group companies are also proactively taking action in waste
reduction through such methods as achieving zero landﬁll waste. We are also actively
taking part in regional exchange events and because of this were selected for the 1st"Environmental Contributions Prize". Also, we gathered all members in charge of ourdomestic aﬃliated companies to hold benchmarking meetings where energy-saving
activities and reducing discarded materials etc. were discussed using"Genchi-Genbutsu" (actual materials at actual locations).

Kaiyo Gomu Co., Ltd.

DATA

Liquefied Natural
Gas tank
Affiliate company information exchange meeting● Location: Kihokucho Kitamurogun Mie Prefecture● Established: Nov , 1931
● Capital: 36 million yen● Operations content Production and sales of industrial and household elastomer
products, resin products● ISO14001 certiﬁcation acquired in December 2001
● ISO9001 certiﬁcation acquired in December 2003

TG Kirloskar Automotive Pvt. Ltd.
Working with regions to preserve the environment

TG Kirloskar (TG Kirloskar Automotive Pvt. Ltd.）TG Kirloskar, which stands in Toyota Techno Park (Bangalore, India) is a corporation
venture between our company, Kirloskar (KOEL), and Toyota Tsusho Corporation. They
manufacture safety systems products and interior and exterior parts. For the sake of
reducing the environmental burden of their manufacturing process, the company hastaken numerous CO2 emissions reduction measures such as using high eﬃciency lights
systems and switching over to electric motor forklifts. They have also minimized theiruse of packaging materials and are actively implementing discarded materials
reduction measures such as the reuse of plastic discarded materials. Through these
activities, they have steadily reduced their CO2 emissions and discarded materials
quantities per sales, and have already achieved the goals set for 2010. They have since
set even higher goals, and are promoting environmental burden reduction activities inwhich all employees participate. Also, they plan and hold events to raise environmental
awareness among children. In June of 2008, their top management participated inenvironmental slogan/picture contests and tree planting festivals at local elementary
schools. Additionally, based on the idea that "Corporations are brought to life byregional society", they are proactively conducting social contribution activities such as
regional cleanups and contributing stationery.
DATA

Environmentally Focused Month events
at local primary schools● Location: Bangalore (Rural) District, 562109, India● Established: Sep, 1998
● Capital:220 million rupee● Their chief product is vehicle safety system products, and they also manufacture and sell internal and external parts● ISO14001 certiﬁcation acquired in January 2002
● TS16949 certiﬁcation acquired in January 2003
● OHSAS9001 certiﬁcation acquired in May 200834

TOYODA GOSEI REPORT 2009

Environmental management

Management

Environmental Report

Toward further dissemination of LED products that are not as harmful to the environment
LED illumination devices use little electricity and have a long life, so they are

Also, in September we opened an ordinary residential model house thateﬀective for curtailing CO2 emissions and reducing waste. In order to foster

uses LED illumination for everything from primary interior illumination to

the wide dissemination of LED at our company, we are conducting

ambient and exterior lighting, and we accomplished the all-LED Housing.

development and production of everything, from the chips to the devices.

The dissemination of LED to households is expected to create a pleasantBecause our LEDs have light source colors that match the needs ofmaintenance-free lifestyle and promote reduction of CO2 emissions andcustomers, product characteristic emphasis is also possible, and they arewaste. Also, we teamed up with illumination manufactures and submitted

being used chieﬂy in shops and operation sites . The color technology has

LED items for display at the Lighting Fair held at Tokyo Big Sight, and drew

drawn attention in a wide variety of ﬁelds, and in the future they aremuch attention from fairgoers. At the same time we are moving forward

expected to be utilized for health and pleasant space uses such as color

with preparations for the general household illumination devices going on

therapy at medical facilities and elimination of bacteria in housing withsale in 2009, and we are taking action to develop products so that we canphotocatalysts.

oﬀer a wide array of the LED products that are better for the environment.

In 2008 we changed the streetlamps at our company from sodium lamps to
LED illumination systems and reduced the amount of electricity consumed.

■ Housing interior illumination■ Oﬃce / Plant / Shop illumination

Lifecycle

Power consumption Maintenance costs

Fluorescent lamp 2 years 291,840kW/11 years
38 unitsLED

38 units

11 years 223,104kW/11 years

2.93million yen/11 years

72t

2.24million yen/11 years

55t

Reduction
rate:

24%

Power consumption

Maintenance costs

CO2

Incandescent lamp 1 year 763,200kW/18 years
29 unit

8.81million yen/18 years

187t

0.88million yen/18 years

19t

Power consumption Maintenance costs

CO2

2 years 1,717,968kW/11 years 33.05million yen/11 years

422t

11 years

100t

LED

29 units

18 years

76,320kW/18 years

Estimation at 10 hours/day of lighting

Estimation at 6 hours/day of lighting■ Outdoors illumination■ Street scenery lighting

Lifecycle Power consumption

Maintenance costs

Sodium lamp 4 years 84,480kW/11 years 0.85million yen/11 years
8 unitsLED

8 units

11 years 26,496kW/11 years

Estimation at 10 hours/day of lighting

35

Lifecycle

CO2

0.27million yen/11 years

Lifecycle

CO2
21t
7t

Reduction
削減率
rate:

24
69％%

Fluorescent lamp +incandescent lamp
1,530 unitsLED

1,530 units

408,960kW/11 years

Estimation at 10 hours/day of lighting

7.87million yen/11 years

Reduction
削減率
rate:

24
90％%

Reduction
削減率
rate:

24
76％%

TOYODA GOSEI REPORT 2009

Cooperation with society

Disclosing environmental cost information

We are taking the 60th anniversary in 2009 of the founding of our company

By completing environmental countermeasures that require considerable

as an opportunity to promote "Aﬀorestation at plant sites". The central

investment such as the introduction of co-generation at each operations

ﬁgure of the aﬀorestation eﬀort is Yokohama National University Professor

site, the most signiﬁcant environmental costs for ﬁscal 2008 were from

Emeritus Akira Miyawaki. The "real aﬀorestation" advocated by him involves

research/development and the changeover to re-pellet of resin materials.

the planting of saplings of numerous types of trees (beech, evergreen, oak

The results in economic terms included the reduction in waste disposaletc.) that are indigenous to the area's natural environment and in the future

expenses stemming from waste material source countermeasures andthey will be made up of three sizes: tall, medium, and short, and will result

recycling, and also the reduction of electricity expenses through morein forests in which diverse types of trees are mixed together. These forests

eﬃcient utility equipment.

Environmental Report

Begin "aﬀorestation at plant sites"

are durable, and are "forest of life" that protect people and the planet
through such functions as noise protection, dust protection, and water■ Environmental Cost

puriﬁcation.
In February of 2009 we invited Professor Akira Miyawaki to hold an

Cost incurred within the operational area*2
Cost for management activities*3

the "Aﬀorestation at plant sites" of the Heiwacho Plant. In November of

Cost for dealing with environmental damage*5

part in the planting of about 11,000 saplings in an approx. 3,700 square
meter area surrounding the plant.
Aﬀorestation at plant sites does not just entail the planting of trees on thatday; by having employees work hard in landscaping and mound creation at

Cost for social contributions*4

Total

plants starting next year.

Total of domestic aﬃliated companies
—
2.0
0.2
0.1
0.1
2.4

*1 Cost for research and development of products to reduce environmental impacts.
*2 Cost to reduce environmental impacts generated in production, such as pollution control,
energy saving, and waste disposal.
*3 Cost for management, including education, maintenance of the environmental management system,
and measurement.
*4 Cost for such measures as forestation and beautiﬁcation.
*5 Cost for dealing with environmental damage caused by business operations.

■ Eﬀects

the planting site, we aim to cultivate a sense of oneness with and feelings
about the importance of nature, and we plan to do the same thing at otherToyoda Gosei
4.5
13.5
1.1
0.2
1.9
21.2

Cost for research and development*1"Aﬀorestation at plant sites Lecture" and an "On-site Instruction" and began
2009 we plan to have employees, their families, and regional residents take

(Unit: hundred million yen)Type of cost

(Unit: hundred million yen)

Economic eﬀect*6
Total of domestic aﬃliated companies
Toyoda Gosei

Type of eﬀect
Energy cost
Cost for waste processing Total

1.5
6.8
8.3

Total
Type of eﬀect

1.0
1.1
2.1
Physical eﬀect*7

Prevention of global warming(amount of CO2 reduced)

5,362t-CO2

Reduction of waste disposal(amount of waste reduced)
Law observance activities

1,778t
P37 Law Observance Activity
Please refer to the homepage for domestic plant data

*6 The economic eﬀect calculated here covers that which can be grasped based on solid ground.
*7 Physical eﬀects are calculated for Toyoda Gosei alone.

■ Changes in Environmental Cost
On-site Instruction at Heiwacho Plant¥billion

Toyoda Gosei

4

Total of domestic
aﬃliated companies

0.24
2■ Changes in Economic Eﬀect¥billion

Toyoda Gosei

1.2

Total of domestic
aﬃliated companies

0.21
0.83

2.12

0.6

Afforestation at plant sites Lecture

0

'04

'05

'06

'07

'08

(Fiscal year)

0

'04

'05

'06

'07

'08

(Fiscal year)

36

TOYODA GOSEI REPORT 2009

Legal Compliance Activity
In order to observe the laws and regulations while promoting corporate activities,
we are arranging a strict survey and check management system.
Highlight of ﬁscal 2008

Tackling "Zero Cases of Non-compliance and Complaints" Activities at Toyoda Gosei Group and reforming our inspection methods and management systems
Expanding the electronic manifest to our entire company

Environmental Report

Thorough water quality management

Conserving Soil/Groundwater

We are thoroughly conducting water quality management of production

We are taking action to investigate and purifysite drainage. At plants that dispose of drainage in inland waterways andcontamination by toxic substances such as trichloroethylene used as athrough rivers in particular we strive to maintain water quality in thecleaner in the past.

disposal of drainage after the cleanups following the installation of nitrogen

We installed an observation well verifying contamination conditions atand phosphorus disposal devices.

every plant and have conﬁrmed regularly that there is no soil or■ Changes in the Volume ■ Changes in the Volume ■ Changes in the Volumeof Nitrogen Emittedof Phosphorus Emittedof COD Emitted

groundwater contamination by oil or substances targeted by the Soil

6.0
4

0

'06 '07'08

1

Volume emitted (in tons)

Volume emitted (in tons)

Volume emitted (in tons)

8

0.66
0.5

0

'06 '07(Fiscal year)'08

8

Pollution Countermeasures Law.
Plants4
1.8
0(Fiscal year)

The former
Nagoya Plant
Haruhi Plant'06 '07'08(Fiscal year)

soil/groundwater

Inazawa Plant

Objects

Situation of countermeasure
After the excavation removal, puriﬁed soil was
backﬁlled and completed in 2006.
We completed puriﬁcation measures (in August of 2008) and
Groundwater continue to conﬁrm that standard value established by regulations
Puriﬁcation in progress (proactively purifying while
Groundwater the possibilities of oﬀ-site pollutions found)
Since the material without our use records was detected in the past,
Groundwater only measurement result is reported regularly to the government.
Soil(Target areas: the 4 plants in Haruhi, Inazawa, Heiwacho, and Seto)

Preserving the atmosphere through a changeover to natural gas

Taking action toward "Zero Cases ofNon-compliance and Complaints" Activities

As countermeasures against the acid rain-causing Nitrogen Oxide (NOx) and
Sulfur Oxides (SOx) generated from boilers, we changed the fuel types of 9

For the sake of thorough compliance, at Toyoda Gosei Group we are taking

boilers over from heavy oil A to natural gas.

action toward "Zero Cases of Non-compliance and Complaints" Activities
and striving to strengthen management through more sharing of■ Changes in the Volume of
Nitrogen Oxides (NOx) Emitted

79

70

0

'06 '07'08

Volume emitted (in tons)

Volume emitted (in tons)

140■ Changes in the Volume of
Sulfur Oxides (SOx) Emitted
20

Strengthening our waste management system

100(Fiscal year)

information and mutual observation.

6

Waste-producing companies manage waste products using manifests(industrial waste management form) by the law to verify that they have

'06 '07'08(Fiscal year)

appropriately disposed of their own industrial waste. When consigningindustrial waste disposal, we must ﬁrmly conduct manifest issuing andcollection management. Our company has used manifests that consist of 7

Proper disposal and storage of equipment containing PCB

sheets to observe by the law and streamlining of operations. We cooperated
with industrial waste disposal contractors and beginning in ﬁscal 2009

Used electrical condensers and ﬂuorescent stabilizers that contain harmful

introduced the electronic manifest at all our company's sites.

and recalcitrant PCB (Polychlorinated Biphenyl) are carefully stored, and wehave now disposed of 65 such devices.
Equipment
containing PCB

Condensers forelectricity use
Fluorescentstabilizers

37

Number ofequipments

Situation of countermeasure̶Properly disposed at the Toyota Oﬃce of the Japan
Environmental Safety Corporation in ﬁscal 2006

Approx. 1200

Appropriately stored (properly disposed sequentiallywhen PCB disposing facility is fully-equipped)

Please refer to the homepage for environmental data.
http://www.toyoda-gosei.com/

Third-party Opinion
With regard to the Toyoda Gosei Report 2009, opinions from third parties have been received.

As symbolized by the Big Three in America which is still
suﬀering from reconstruction, the automotive industry is
exposed to the severe environment due to the reduced
worldwide market. Under such circumstances, Toyoda Gosei,
which has 95% of its business in automotive parts, has an 18%
decrease in sales compared to the previous year but it still
manages to be in the black. They are requested to put in eﬀort
in reducing the cost via dynamic management innovations andsound ﬁnancial management.
During such diﬃcult economic times, a worrying problem isthat of downsizing of manpower. As seen from the changes in
the number of employees in Japan, there has been an increaseof approx. 300 workers since the previous year. On the other
hand, there has been a decrease of approx. 1500 workers inoverseas. Regarding the reduction of manpower overseas due
to 2 overseas sites decrease (one has been put oﬀ Toyoda
Gosei’s subsidiary company, the other has been liquidated). As amatter of fact, eﬀorts such as a wage/overtime work control andthrough operational eﬃciency leading to the maintenance of
employment are put in.
For this report, it is an integration of the Social andEnvironmental Report and the Annual Report, with new
chapters including the “Business Report”, “Management Report”
and “Financial Report”. These 3 new chapters contribute to the“Economical Report”, and are expected to report on the Triple
Bottom Line of the economic, social and environmental issues.
However, it is diﬃcult to say if this report is giving an overall
picture of management and ﬁnancial situations. For instance, tounderstand the enterprise named Toyoda Gosei more, I would
like to see the information concerning the sales compositions
according to customers and the compositions of employees. As
for the ﬁnancial report, only the ﬁnancial data are disclosed,
while explanations on the changes in the business environmentthat contribute to the data background are desired.
Additionally, I would like to ask for proactive disclosure of
information for themes with the great interest of the
stakeholders such as the concern on the reduction of
manpower.
The special feature is on the “manufacturing” and “humanresource development” that support the technology based

Mr. Hiromitsu Kumetani
President and CEO of Nord Institute forSociety and Environment
Commissioner of NPO Workers Club for
Eco-harmonic Renewable Society

enterprise. From the readers' point of view, there are notenough concrete content and depth on the strategies adopted
by Toyoda Gosei on how to strengthen their technology
development and human resources development in diﬃcult
times like this.
With regard to compliance, there is a description on the“compliance adherence rate survey” that is given to all theemployees. I expect a report with the results of the survey andutilized its improvement activities. In addition, I am interested in
the “lecture on a lay judge system”.
It is possible to look for steady advancement about the activities
from the environmental aspect. This is especially so in the
reduction of the release of incineration waste and that material
recycling is exceeding thermal recycling, via eﬀorts in re-pellet.
Moreover, in view of the Conference of the parties to theConvention on Biological Diversity (COP10) which will be held in
Aichi Prefecture next year, it is important that there is“aﬀorestation at plant sites” which is started by the “Heiwacho
Plant”.
It seems that while looking forward to the 60th anniversary of
the business, in the automotive parts ﬁeld, there will be
important strategies on the development of parts that cater toeco-cars and compact cars, with respect to the expected highdemand of hybrid system and electric cars. Furthermore, theautomotive part market reduction crisis should be regarded as achance to bolster residential LED illumination. Also, the system
supplier of the non-automotive parts division has anopportunity to make an impression, while there have been highexpectations on the making of “enterprises that are
independent on petroleum”.

Response to Third-party Opinion
After the previous ﬁscal year, we had an opinion from Mr.
Hiromitsu Kumetani, Commissioner of NPO “Workers Club for
Eco-harmonic Renewable Society”
This year's report will present a clearer overall picture on the
Toyoda Gosei Group with the integration of the Annual Report
and the Social and Environmental Report.
While there has been a step forward from the previous year inthat this report being on the triple bottom line of economy,society and the environment, there has been indications that
this report fails to give clear and comprehensive overall picture
on management and ﬁnance. It is thought that the whole imageof management could be conveyed on the page of “Message
from president”. In the coming year, eﬀorts will be made in thedisclosure of not only the ﬁnancial data, but also aﬀairs of the
ﬁnancial and economic aspects, so that the stakeholders will
have a better understanding. Moreover, referring to thegovernance/social aspects, there have been plans of

introducing the users of the child care support system, athorough compliance, and a strengthening of the internal auditof the compliance. In the future, such results are revealed, andthe results on the improved activities by PDCA will be seen.
As for the environmental aspect, the evaluation on the result of
conversion to material recycling has been obtained, and it will
aim towards the activities of eﬀective use of resources while
cutting the emission of waste.
Based on the comments we received, we will make an
improvement on information disclosure from now onward. At
the same time, we will put eﬀort in the style of continuous
spiraling to improve the contents and the results for easycomprehension.
General Administration Division, General & Public Aﬀairs Dept.
Plant & Environment Engineering Division Environment
Administration Dept.

38

TOYODA GOSEI REPORT 2009

Data Highlights

We strived to develop new products and actively expand sales in ﬁscal
2008, The consolidated net sales are 546.3 billion yen, which is adecrease as compared to 662.4 billion yen in the previous year.
The ordinary income has also decreased from 50.5 billion yen in theprevious year to 12.1 billion yen.

Financial Report

The net income is 3.9 billion yen , which is a decrease from the 30.8
billion yen in the previous year.
The details of the ﬁnancial data are published in the following pages.

■ Net Sales■ Ordinary Income /Net Income(billion)(billion)

700

60

662.4
593.4

600
500

50.5

50

546.3

498.4

40

435.5

400

31.3

30

300

20

200

0

2005

2006

2007

2009 (Years ended

2008

15.9

12.1

10.7

10.5

10

100

20.0

17.4

30.8

3.9

0

2005

March 31)

2006

2008

2007

2009 (Years ended

March 31)

Ordinary Income■ Total net assets■ Capital Investment /R&D Expenses(billion)(billion)

60

300
253.9

250

211.7

150

30

100

20

50

10

0

2005

2006

2007

2009 (March 31)

2008

24.5

0

53.1

45.6

42.2

40

186.8

168.6

58.2

54.9

50

224.5

200

Net Income

2005

25.3

2006

25.9

24.3

24.8

2008

2007

2009 (Years ended

March 31)

Capital Investment■ Changes in the Number of Employees■ Number of employees
by Region (March 31)

21,00019,03718,000Europe and Africa
1,534(5.9 %)

17,506

16,61415,00012,0009,000

11,805

10,374
6,905

7,046

7,311

7,999

Asia and
Oceania
11,572(44.9 %)

8,286

6,000
3,000
0

39

2005

2006

R&D Expenses

2007

2008

2009

(March 31)

Domestic

Overseas

Number of
employees
25,792

Japan
8,286(32.1 %)

North America
4,400(17.1 %)

Toyoda Gosei Co., Ltd. and its Consolidated Subsidiaries
Years ended March 31(Amount: million of yen)(Amount: thousandsof U.S. dollars)

2008

2007

2006

2005

2009

¥546,380¥662,497¥593,454¥498,427¥435,538$5,562,252

Operating income

15,83352,12531,55019,676

17,191

161,183

Ordinary income

12,15550,541

31,34720,023

17,464

123,740

Net income

3,951

30,802

15,943

10,787

10,58540,222¥242,893¥279,701¥252,707¥199,804¥150,834$2,472,697

Depreciation and amortization

41,25840,30936,82932,54928,518419,994

Capital expenditures

59,42954,612

55,69046,64042,939592,579

R&D expenses

24,83725,98924,321

25,312

24,502

252,845

30.55¥ 238.61¥ 123.78

30.55

237.97

123.63

81.73

80.28

0.31

Total net assets per share

1,523.16

1,781.08

1,591.52

1,449.27

1,305.07

15.51

Cash Dividends per share

36

46

26

19

18

0.37

Total assets¥391,757¥476,741¥459,087¥ 392,671¥342,439$3,988,160

Total net assets

211,702

253,961

224,551

186,838

168,644

2,155,166

Common stock

28,02728,02728,02728,02728,027285,320

Number of shares outstanding(excluding treasury stock) (thousands of shares)

129,334

129,307

128,826

128,745

129,061̶¥ 47,843¥ 75,229¥ 67,325¥ 42,426¥ 40,323$ 487,051(55,945)(55,291)(52,963)(48,566)(48,690)(569,531)

Net cash provided by (used in) financing activities

5,604(20,742)

9,307

4,939

1,796

57,050Cash and cash equivalents at end of year

42,70153,372

55,97029,53529,383$ 434,704

Return on equity (ROE) (%)

1.8

14.2

8.1

6.1

6.4

̶

Return on assets (ROA) (%)

2.8

10.8

7.4

5.4

5.3

̶

Return on sales (ROS) (%)

2.9

7.9

5.3

3.9

4.0

̶

31.4％

22.5％

32.7％

29.0％

25.7％

̶

13.0

24.1

13.7

16.5

17.9

̶

EBITDA (millions of yen, thousands of U.S. dollars) ¥ 50,666¥ 89,493¥ 67,687¥ 52,297¥ 46,263$ 515,789

25,792

27,03623,92518,851

17,729̶

For The YearNet sales

Overseas sales

Financial Report

2009

TOYODA GOSEI REPORT 2009

Consolidated Five-Year Financial Summary

Per share of common stock (yen, U.S. dollars)
Net Income per share - basic
Net income per share — diluted

¥

¥

81.77

¥

80.32

$

0.31

At Year-End

Cash FlowsNet cash provided by operating activities
Net cash used in investing activities

Indices

Debt/equity ratio (%)
Interest coverage (times)

Number of employees at year-end

Notes 1. U.S. dollar amounts have been translated from yen, for convenience only, at the rate of ¥98.23 = US$1, the exchange rate on March 31. 2009.
Notes 2. Net income per share, ROE and ROA are computed based on the average number of shares, total net assets and total assets, respectively, for each year.
Notes 3. Debt/equity ratio = Interest-bearing debt / Total net assets
Notes 4. Interest coverage = (Operating income + Interest and dividends income) / Interest expenses
Notes 5. EBITDA = Income before income taxes + Interest expenses - Interest and dividends income + Depreciation and amortization

40

TOYODA GOSEI REPORT 2009

Consolidated Balance Sheets
Toyoda Gosei Co., Ltd. and its Consolidated Subsidiaries
March 31, 2009 and 2008

■ ASSETS

Current assets(Amount: million of yen)increase anddecrease■ LIABILITIES¥145,891 ¥203,863¥(57,972)

Current liabilities

2009

2008

Financial Report

Cash and cash equivalents

42,78550,552(7,767)

Trade notes and accounts receivable

55,310100,322(45,012)

Short-term investments

215

3,110

(2,895)Inventories

29,68934,162(4,473)

Deferred tax assets

4,562

6,582

(2,020)

Other current assets

13,411

9,238

4,173

(82)

(104)

22

207,924

232,046(24,122)

Property, plant and equipment

204,515228,019(23,504)

Buildings and structures

60,204

66,034(5,830)Less - allowance for doubtful accounts
Fixed assets

Machinery, equipment and vehicles

80,288105,617(25,329)

Tools, furniture and fixtures

26,74122,090

4,651

Land

21,71322,746(1,033)

Construction in progress

15,566

11,530

4,036

3,409

4,027

(618)

Goodwill

111

108

3

patent rights

187

277

(90)

Software

1,671

1,535

136

Other intangible assets

1,438

2,105

(667)

2008

increase anddecrease¥101,314 ¥154,806 ¥ (53,492)
42,59378,901(36,308)

Short-term bank loans

14,557

19,845(5,288)

Accrued expenses

18,83424,891(6,057)

Accrued income taxes

1,653

7,834

(6,181)

Provision for directors’ bonuses

223

381

(158)

Provision for product warranties

839

1,494

(655)

Deposits received from employees

4,601

4,699

(98)

Other current liabilities

18,01016,757

1,253

78,74067,973

10,767

Bonds

10,00010,0000Long-term bank loans

41,83927,402

14,437

Deferred tax liabilities

Long-term liabilities

1,820

5,400

(3,580)

Provision for Loss on Liquidationof Affiliates

−

2,224

(2,224)

Provision for retirement benefits

22,603

20,628

1,975

Reserve for retirement benefits for
directors and corporate auditors

1,562

1,572

(10)

Other long-term liabilities

915

744

171

¥180,055 ¥222,779 ¥ (42,724)■ NET ASSETS

Shareholders’ equity¥209,766 ¥214,867 ¥ (5,101)

Common stock

28,02728,0270

Capital surplus

29,81529,813

2

Retained earnings

153,409

158,574(5,165)

Treasury stock at cost

(1,486)(1,548)62

Valuation and translation adjustments(12,769)

15,438(28,207)

2,872

7,316

(4,444)(15,642)

8,122(23,764)

Investments and other assets

37,942

40,831(2,889)Investments in securities

19,361

21,949(2,588)prepaid pension expenses

1,531

2,889

(1,358)Deferred tax assets

11,712

7,911

3,801

Subscription rights to shares

413

221

192

Other investments and other assets

5,420

8,120

(2,700)Minority interests in consolidated
subsidiaries

14,292

23,434(9,142)Less - allowance for doubtful accounts

(84)

(38)

(46)

Total net assets

211,702

253,961(42,259)¥391,757 ¥476,741¥(84,984)

Total assets

41

2009

Trade notes and accounts payable

Total liabilities

Intangible assets(Amount: million of yen)

Net unrealized gains or losses
on other securities
Foreign currency translation
adjustments

Total liabilities and net assets ¥391,757 ¥476,741 ¥ (84,984)

(Amount: million of yen)

2008

increase anddecrease¥546,380¥662,497¥(116,117)

492,302570,251(77,949)

54,07892,245(38,167)

38,244

40,119(1,875)

15,83352,125(36,292)

4,418

4,886

(468)

1,008

1,232

(224)

̶

91

(91)

3,409

3,562

(153)

Non-operating expenses

8,097

6,471

1,626

Interest expenses

1,293

2,213

(920)

Equity in net losses of affiliates

1,629

̶

1,629

Foreign exchange loss

1,058

1,513

(455)

Other non-operating expenses

4,115

2,743

1,372

12,15550,541(38,386)

519

9

510

Reversal of Allowance for Bad Debts

26

9

17

Reversal from the Provision for Loss on Liquidation of Affiliates

486

̶

486

6

̶

6

3,549

2,347

1,202

Investments in securities

9

182

(173)

Loss on Liquidation of Affiliates

̶

2,164

(2,164)

3,477

̶

3,477

62

0

62

9,125

48,203(39,078)

Income taxes — current

3,200

14,840(11,640)

Income taxes - deferred(1,005)(1,717)712

Minority interests in consolidated subsidiaries

2,979

4,277

(1,298)3,951¥ 30,802¥ (26,851)

Net Sales
Cost of sales
Gross profit
Selling, general and administrative expenses
Operating income
Non-operating income
Interest and dividends income
Equity in net earnings of affiliates
Other non-operating income

Ordinary Income
Extraordinary gains

OthersExtraordinary losses

Impairment loss on long-lived assets
OthersIncome before income taxes and minority interests

Net Income¥

Financial Report

2009

TOYODA GOSEI REPORT 2009

Consolidated Statements of Income
Toyoda Gosei Co., Ltd. and its Consolidated Subsidiaries
For the years ended March 31, 2009 and 200842

TOYODA GOSEI REPORT 2009

Consolidated Statements of Changes in Net Assets
Toyoda Gosei Co., Ltd. and its Consolidated Subsidiaries
For the years ended March 31, 2009 and 2008

(Amount: million of yen)

Total
Net unrealized Foreign
Subscription Minority
Total
Common Capital Retained Treasury
gains or losses currency valuation and rights to interests in Total net
stock
shareholders'stocksurplus earnings at costtranslation translationon othershares consolidated assets
equitysubsidiaries
securities adjustments adjustments

Balance at March 31, 2008

¥28,027 ¥29,813 ¥158,574 ¥ (1,548) ¥214,867¥7,316¥8,122 ¥15,438¥221 ¥23,434 ¥253,961

Changes of items during the period(6,336)(6,336)(6,336)

Increase (decrease) due to increase in theaffiliates accounted for under the equity method

216

216

216

Increase(decrease)due to the changes in accounting
treatment of controlled foreign subsidiaries(2,793)(2,793)(2,793)

Increase(decrease)due to the changes in accounting
term of consolidated subsidiaries

(202)

(202)

(202)

Net income for the period

3,951

3,951

3,951

(4)

(4)

(4)

65

68

68

Dividends paid
Financial Report

Repurchase of treasury stock2

Disposal of treasury stock
Change to items other than shareholders’ equity
during accounting period(4,443) (23,764) (28,208)

191(9,141) (37,158)(5,100)(4,443 (23,764) (28,208)

191(9,141) (42,258)

Balance at March 31, 2009

¥28,027 ¥29,815 ¥153,409 ¥ (1,486) ¥209,766¥2,872 ¥ (15,642) ¥ (12,769)¥413 ¥14,292 ¥211,702

Balance at March 31, 2007

¥28,027¥10,995¥ 56

2

Changes of items during accounting period(5,164)

61¥29,723 ¥132,123 ¥ (2,574) ¥187,295¥ ,6,739¥17,735¥19,463 ¥ 224,551

Changes of items during the period
Dividends paid
Increase and decrease due to increase in affiliates
accounted for under the equity method

Net Income for the period(4,386)(4,386)(4,386)

34

34

34

30,80230,80230,802

(9)

(9)

(9)

1,040

1,129

1,129

Repurchase of treasury stock
89

Disposal of treasury stock
Change to items other than shareholders’ equity
during accounting period

89

Changes of items during accounting period
Balance at March 31, 2008

43

¥28,027

26,451¥29,813 ¥158,574(3,679)1,382(2,296)

164

3,970

1,838

27,571(3,679)1,382(2,296)

164

3,970

29,410¥ (1,548) ¥214,867¥7,316¥8,122¥15,438

¥221

1,030

¥23,434 ¥ 253,961

Toyoda Gosei Co., Ltd. and its Consolidated Subsidiaries
For the years ended March 31, 2009 and 2008

(Amount: million of yen)

2008

increase and decrease

Cash flows from operating activities
Income before income taxes and minority interests
Depreciation and amortization
impairment loss
Amortization of goodwill
Increase (decrease) in allowance for doubtful accounts
Increase (decrease) in provision for product warranties
Increase (decrease) in provision for Loss on Liquidation of Affiliates
Increase (decrease) in provision for retirement benefits
Increase (decrease) in prepaid pension expenses
Increase (decrease) in reserve for retirement benefits for directors and corporate auditors
Interest and dividends income
Interest expenses
exchange gain and loss
Equity in net earnings of affiliates
Investments in securities appraisal loss and sale profit and loss
Share change profit and loss
Loss on sales or disposal of property, plant and equipment, net
Increase (decrease) in receivables
Increase (decrease) in inventories
Increase (decrease) in other current assets
Increase (decrease) in payables
Increase (decrease) in other current liabilities
Others, net
SubtotalInterest and dividends income received
Interest expenses paid
Income taxes paid
Cash flows from investing activities
Payments for purchases of investment securities
Proceed from sales and redemption of investments in securities
Payment from the acquisition of the subsidiary company stocks
Payment for intangible assets and purchase of property, plant and equipment
Proceeds from sales of property, plant and equipment
Payments of long-term loans receivable
Proceeds from collections of long-term loans receivable
Payments from the acquisition of other forms of investments
Payments from the sales of other forms of investments
Cash flows from financing activities
Increase (decrease) in short-term loans payable
Proceeds from long-term loans
Repayments of long-term loans
Proceeds from issuances of bonds
Repayments of bonds
Proceeds from payment by minority shareholders
Proceed from disposal of treasury stock
Payments for repurchase of treasury stock
Cash dividends paid
Cash dividends paid to minority shareholders
Translation adjustments of cash and cash equivalents
Net increase (decrease) in cash and cash equivalents
Cash and cash equivalents at beginning of year
Amount of increase(decrease)of cash and cash equivalent due to the changes in the consolidation scope¥47,843¥75,229¥(27,386)

9,125

48,203(39,078)

41,25840,309

949

3,477

̶

3,477

Amount of increase of cash and cash equivalent of beginning of period due to changes in the accounting period of consolidated subsidiaries

Cash and cash equivalents at end of year

39

39

0

(11)

(112)

101

(594)

727

(1,321)(2,224)2,224(4,448)

285

652

(367)

411

(521

932

16

340

(324)

(1,008)(1,232)

224

1,293

2,213

(920)

123

1,270

(1,147)

1,629

(91)

1,720

9

164

(155)

60

̶

60

555

1,385

(830)

37,973(3,552)

41,525

433

(896)

1,329

1,913

(1,074)

2,987(33,073)(2,131)(30,942)

1,049

1,260

(211)

311

195

116

63,05489,373(26,319)
(280)

1,034

1,314

(1,292)(2,212)920(14,953)(13,246)(1,707)(55,945)(55,291)

(654)

(376)

(9)

(367)

40

164

(124)

(191)

̶

(191)

(56,582)(56,118)

(464)

1,427

696

731

(172)

(4)

(168)

7

7

0

(167)

(210)

43

69

183

(114)

5,604

(20,742)

26,346(2,209)(16,457)

14,248

16,2091,922

14,287(1,285)(2,319)

1,034

̶

9,947

(9,947)

̶(10,000)

10,000

227

505

(278)

66

1,129

(1,063)

(4)

(9)

5

(6,336)(4,384)(1,952)(1,062)(1,075)13(4,746)(1,794)(2,952)(7,244)(2,598)(4,646)53,372

55,970(2,598)(4,548)

̶

(4,548)

1,122

̶

1,122

¥42,701¥53,372¥(10,671)

Financial Report

2009

TOYODA GOSEI REPORT 2009

Consolidated Statements of Cash Flows

44

Global Network With 45 facilities in 16 nations and regions around the world (Except Japan)
As of June.2009
豊田合成（天津）精密製品有限公司

Toyoda Gosei UK Ltd. ■Toyoda Gosei（ Tianjin）Precise Plastic Co., Ltd. ■Toyoda Gosei Europe N.V.

天津豊田合成有限公司

Tianjin Toyoda Gosei Co., Ltd. ■■■Toyoda Gosei Europe N.V. Germany Oﬃce

天津星光橡塑有限公司

Tianjin Star Light Rubber and Plastic Co., Ltd. ■豊田合成（張家港）科技有限公司

Toyoda Gosei（ Zhangjiagang）Co., Ltd. ■豊田合成（張家港）塑料製品有限公司

Toyoda Gosei（ Zhangjiagang）Plastic Parts Co., Ltd. ■豊田合成（上海）商務諮詢有限公司

South Yorkshire
Zaventem
Saarbrucken

Toyoda Gosei（ Shanghai）Co., Ltd.
Klasterec
Jennersdorf

豊田合成光電貿易（上海）有限公司

Toyoda Gosei Czech, s.r.o. ■■■LEXEDIS Lighting GmbH ■Toyoda Gosei Opto-Electronics（ Shanghai）Co., Ltd.

Tianjin
本社 Headquarters

Zhangjiagang

Metzeler Automotive Proﬁles India Pvt. Ltd. ■ShanghaiFuzhouToyoda Gosei India Pvt. Ltd. ■Ghaziabad
RajasthanBangalore

FoshanHaiphong

Taiwan福州福裕橡塑工業有限公司

Fuzhou Fu-Yue Rubber & Plastic Industrial Co., Ltd. ■台裕橡膠工業股 有限公司 Tai-yue Rubber Industrial Co., Ltd. ■■豊裕股 有限公司 Fong Yue Co., Ltd. ■■Chonburi
Samutsakorn

豊田合成（佛山）橡塑有限公司 Toyoda Gosei（Foshan）Rubber Parts Co., Ltd. ■■豊田合成（佛山）汽車部品有限公司 Toyoda Gosei（Foshan）Auto Parts Co., Ltd. ■Toyoda Gosei Haiphong Co., Ltd. ■Jakarta

TG Kirloskar Automotive Pvt. Ltd. ■■DurbanSouth Australia

Toyoda Gosei South Africa（Pty）Ltd. ■Bridgestone TG Australia（ Pty）Ltd. ■■P.T. INOAC TG Indonesia
P.T. Toyoda Gosei Safety Systems Indonesia ■Toyoda Gosei Asia Co., Ltd.
Toyoda Gosei（ Thailand）Co., Ltd. ■■■Toyoda Gosei Rubber（ Thailand）Co., Ltd. ■■Pongpara Codan Rubber Co., Ltd. ■■45

Headquarters

Kitajima Technical Center

Miwa Technical Center

Toyoda Gosei Czech, s.r.o.

Toyoda Gosei Asia Co., Ltd.

Tianjin Toyoda Gosei Co., Ltd.

Haruhi Plant

Toyoda Gosei North America Corporation

Production Items■ Interior & exterior parts■ Body sealing products

TG California Automotive Sealing, Inc. ■■ Functional parts■ Safety system products■ Optoelectronic products■ General industry products

TG Kentucky, LLC ■■Daicel Safety Systems America, LLC ■TG Automotive Sealing Kentucky, LLC ■Toyoda Gosei North America Corporation
TG Personnel Services North America, Inc.
TGR Technical Center, LLC
TG Fluid Systems USA Corporation ■Toyoda Gosei Holdings Inc.
Waterville TG Inc. ■Ontario

QuebecSaga Plant ■■Kitakyusyu Plant ■■■■TG Minto Corporation ■Missouri

Osaka Sales Branch

KentuckyTokyo Sales Branch

TG Missouri Corporation ■■Toyoda Gosei Texas, LLC ■TAPEX Mexicana S.A. DE C.V. ■Texas
Matamoros

Utsunomiya Sales Branch

Hiroshima Sales BranchMichiganCalifornia

Iwate Plant ■■Kanagawa Plant ■■Fukuoka Plant ■■■San Luis Potosi

Bisai Plant ■■Inazawa Plant ■■Headquarters

Toyoda Gosei Automotive Sealing Mexico S.A. DE C.V. ■Toyoda Gosei Personnel Services Mexico S.A. DE C.V.

Haruhi Plant ■Seto Plant ■Nagoya City

Kitajima Technical Center
Miwa Technical Center

Shizuoka pref.

Aichi pref.

Nishimizoguchi Plant
Heiwacho Plant ■■■■

Morimachi Plant ■■Inazawa Plant

Morimachi Plant

Bisai Plant

Heiwacho Plant

Seto Plant

TG Missouri Corporation46

Directors structure

As of June 24, 2009

Directors
Chairman of the Board

Akio Matsubara
Vice Chairman of the Board

Takashi Matsuura
President

Hajime Wakayama
Executive Vice Presidents

Tsuneji Obara

Muneo Furutani

Senior Managing Directors

Kuniaki Osaka

Takayasu Hiramatsu

Yuichi Shibui

Managing Directors

Koichi Ota

Nobutaka Ito

Noboru Kato

Kuniyasu Ito

Tsugio Kadowaki

Takasuke Haruki

Nobuyuki Shimizu

Hiromi Ikehata

Yoshiaki Takei

Directors

Nobuo Fujiwara
Kyoji Ikki

Masayoshi Ichikawa

Kanji Kumazawa

Yukio Kawakita

Atsushi Sumida

Corporate Auditors
Standing Corporate Auditors

Hiroyuki Ioku

Ikuo Okada

Yasushi Matsui

Corporate Auditors

Kazuo Okamoto

47

Tsuchio Hosoi

Kazumi Otake

Company Profile

As of March 31, 2009

company emblem / corporate name

Stock Information

Common stock

Stock Exchange Listings

June 15, 1949

Capital28 billion

Number of employees

Non-consolidated
Consolidated

Fiscal year end

March 31

6,631
25,792As of March 31, 2009

Authorized

200,000,000 shares

Issued130,010,011 shares

Major Share holders(Ten from the top)
Number ofshare holding(thousand shares)

Investment ratio

Tokyo Stock Exchange andToyota Motor Corporation

55,45942.65

Nagoya Stock Exchange

The Master Trust Bank of Japan, Ltd. (Trust Account)

10,357

7.96

Japan Trustee Services Bank, Ltd. (Trust Account 4G)

5,851

4.50

Japan Trustee Services Bank, Ltd. (Trust Account)

5,501

4.23

Sumitomo Mitsui Banking Corporation

5,049

3.88

The Dai-ichi Mutual Life Insurance Company

1,866

1.43

The Chase Manhattan Bank NA,
London SL Omnibus Account

1,739

1.33

Nippon Life Insurance Company

1,714

1.31

Mitsubishi UFJ Trust and Banking

Mitsui Sumitomo Insurance Co., Ltd.

1,661

1.27

Corporation Stock Transfer Agency

Tokio Marine & Nichido Fire Insurance Co., Ltd.

1,628

1.25

Number of Shareholders 11,443
Transfer agent

Date of Establishment

Mitsubishi UFJ Trust andBanking Corporation〒137-8081
7-10-11 Higashi-suna,Koto-ku,Tokyo

Names of shareholders(%)

TEL.0120-232-711(Toll free number)
Share Price Range (Tokyo Stock Exchange)
(¥)
5,000

Stock Price

4,000
3,000
2,000
←High

1,000

←Low

0
(thousand shares)

20,000

Trading Volume

10,000
0

2007
2008
2009
2005
2006
4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 (Month)48

Treating Humans andthe Earth Nicely

With regard to “creating an environment that is kind toboth people and the earth” and from the perspective ofenvironmental conservation and the valid use ofresources, three points, three things on which we need tobase our actions are “Don’t make (“Don’t use”) [Tsukuranai],” “Don't throw away [Sute-nai],” and “Don’t leave it toothers [Makase-nai].” Together, these phrases make theslogan “Nicely” (the three “nai's”, which sounds like
“Nicely” when pronounced with a Japanese accent).
“Treating humans and the earth nicely” is the trademarkof Toyoda Gosei's environmental activities.

TOYODA GOSEI CO., LTD.
General Administration Division, General & Public Affairs Dept.

1 Nagahata, Ochiai, Haruhi, Nishikasugai, Aichi,* 452-8564, Japan
Tel: +81-52-400-1055 Fax: +81-52-409-7491

http://www.toyoda-gosei.com/*The address will be changed to"1 Haruhinagahata Kiyosu, Aichi"

as of October 1, 2009 due to governmental district readjustment.
The zip code , telephone number and fax number will not be changed.

This report is made of FSC certiﬁed papers from well managed forest. The ink uses vegetable oil
containing no VOC (volatile organic compounds) and is printed using a printing process thatcreates no harmful waste liquids.
Please recycle this publication.

2009.09.3,500

TP JapanTOYODA GOSEI REPORT 2009

Environmental Data
】 • April, 2008 to March, 2009【

Period【Air】 • Units are as follows: NOx = ppm, PM (particulate matter) = mg/Nm3 • ND: below the minimum determination limit (not detected)

【

Water

】 • Units are all in mg/L except for pH • pH: hydrogen ion concentration • BOD: Biochemical Oxygen Demand • SS: concentration of suspended solids in water• Values shown in the results column are averages of the results of the measurements.

• ND: below the minimum determination limit (not detected) • Values shown in the results column are averages of the results of the measurements.

【 Groundwater 】 • Units are all in mg/L • ND: below the minimum determination limit (not detected).
【 PRTR* Data 】 • Units are in kg *Values less than 1kg are rounded up if ≥0.5 and down if 0.5. There are some cases in which values for total volume and volume handled are not in agreement.

*Pollutant Release and Transfer Register (the registration system monitoring emissions of substances that pollute the environment and moves/transfers of them)

Data on Main Domestic Plants

Haruhi Plant
1 Nagahata, Ochiai,
Haruhi, Nishikasugai,
Aichi, Japan 452-8564■Air (Air Pollution Control Law, prefectural regulations, etc.)
Item measured

ResultDust

Co-generation (gas)

0.05

0.022

NOx

Boilers (gas)

150

51

Co-generation (gas)

600

55

Main Products• Functional parts■Water (Water Pollution Control Law, prefectural regulations, etc.)

Regulation value■Groundwater
Environmental
Standard

ResultTrichloroethylene

0.03

ND

Cis-1,2-Dichloroethylene

0.04

Item measured

ND~0.08**Refer to Toyoda Gosei Report P.37

■No violations of laws, etc.

Regulation value

Result5.8~8.6

7.5

BOD (Biochemical Oxygen Demand)

25

3.9

SS

30

0.9

Oil content

5

ND

Total nitrogen

120

1.4

Total phosphorus

16

0.6

Thiram0.06

ND

Fluorine

80.2

Item measured
pH■No complaints■PRTR Data

Morimachi Plant
1310-128 Mutsumi,Mori, Shuchi,
Shizuoka, Japan
437-0213
Main Products

Volume emitted

Substance nameAmounthandledInto the airBis (2-ethylhexyl) adipate

1,032

0

0

2-imidazolidin thionate

5,505

0

0

Volume moved

Volumerecycled

Total removed Total consumed(processed)(products)

Volume moved
via sewers

Volume moved
as waste

0

0

155

0

0

878

0

0

799

10

0

4,696

Into bodies of water Into the groundN-cyclohexyl-2-benzothiazole
sulfenic amide

7,207

0

0

0

0

1,050

53

0

6,104

Thiram

9,409

0

0

0

0

508

0

0

8,901

Di-n-butyl phthalate

2,772

0

0

0

0

416

0

0

2,356

Bis (2-ethylhexyl) phthalate

5,405

0

0

0

0

792

7

0

4,606

■Air (Air Pollution Control Law, prefectural regulations, etc.)
Item measured■Water (Water Pollution Control Law, prefectural regulations, etc.)

Regulation value

Result

Dust

Boilers (heavy oil)

0.25

0.02

NOx

Boilers (heavy oil)

180

88

■No violations of laws, etc.

Item measured

Regulation value

Result5.8~8.5

7.5

BOD (Biochemical Oxygen Demand)

25

8.0

SS

50

5.4

Oil content

5

0.5

0.06

0.005

8

0.2

0.5

0.2

pH

■No complaints• Body-sealing products• Functional parts

ThiramFluorine
Zinc■PRTR Data
Substance nameAmounthandledVolume moved

Volume emitted
Into the air

Into bodies of water Into the ground

Volume moved
via sewers

Volume moved
as wasteVolumerecycled

Total removed Total consumed(processed)(products)

Antimony and its compounds

6,598

0

0

0

0

330

66

0

6,202

2-imidazolidin thionate

11,575

0

0

0

0

463

463

0

10,649Ethylbenzene

18,603

13,978

0

0

0

3,723

225

0

676

Xylene21,515

16,177

0

0

0

4,333

251

0

753

N-cyclohexyl-2-benzothiazole
sulfenic amide

11,801

0

0

0

0

472

472

0

10,857

Thiuram

20,309

0

0

0

0

1,097

0

0

19,212

1,3,5-trimethylbenzene

1,563

1,174

0

0

0

313

19

0

57

Toluene59,69837,75200019,446

1,227

0

1,273

Bis zinc(N,N-dimethyldithiocarbamic acid)

6,673

0

0

0

0

267

267

0

6,139

Di-n-butyl phthalate

21,186

0

0

0

0

1,059

212

0

19,915Bis (2-ethylhexyl) phthalate

4,850

0

0

0

0

169

35

0

4,647

Phthalic anhydride

1,321

0

0

0

0

61

12

0

1,247

Heiwacho Plant■Air (Air Pollution Control Law, prefectural regulations, etc.)
Item measured

710 Origuchi,
Shimomiyake, Heiwa,
Inazawa, Aichi, Japan
490-1312

Dust

Main Products

NOx• Body-sealing products• Functional parts• Safety system products• Optoelectronic products■Water (Sewerage Law, prefectural regulations, etc.)

Regulation value

ResultRegulation value

ResultBoilers (heavy oil)

0.15

ND

pH

5~9

7.1

Boilers (gas)

0.05

ND

BOD (Biochemical Oxygen Demand)

600

28

Co-generation (gas)

0.05

0.001

SS

600

19

Boilers (heavy oil)

140

76

Oil content

30

0.1

Boilers (gas)

120

62

Total nitrogen

240

7.9

Co-generation (gas)

200

110

Total phosphorus

32

0.5

Fluorine

8

0.3■No violations of laws, etc.

Item measured■No complaints■PRTR Data
Substance nameInazawa Plant
1 Komeyasakai,
Kitajima, Inazawa,
Aichi, Japan
492-8542
Main Products• Interior and exterior parts• Functional parts

AmounthandledVolume emitted
Into the air

Volume moved

Into bodies of water Into the ground

Volume moved
via sewers

Volume moved
as wasteVolumerecycled

Total removed Total consumed(processed)(products)

2-aminoethanol

53,672

5

0

0

107

53,559000Ethylbenzene

7,297

5,929

0

0

0

913

114

0

341

Xylene

9,312

7,560

0

0

0

1,163

147

0

442

Toluene10,487

8,502

0

0

0

1,305

170

0

510

■Air (Air Pollution Control Law, prefectural regulations, etc.)
Item measured
NOx■Water (Water Pollution Control Law, prefectural regulations, etc.)

Regulation value

ResultBoilers (gas)

150

58

pH

Co-generation (gas)

600

175

■Groundwater
Environmental
Standard

ResultTrichloroethylene*1

0.03

ND~0.003*2

Cis-1.2-Dichloroethylene*1

0.04

ND~0.074*2

Item measured*1 Substances that have no record of being used. *2 Refer to Toyoda Gosei Report P.37

■No violations of laws, etc.

Regulation value

Result5.8~8.6

7.2

BOD (Biochemical Oxygen Demand)

25

6.9

SS

30

5.2

Oil content

5

ND

Total nitrogen

120

11.8

Total phosphorus

16

1.2

Hexavalent chromium

0.5

ND

Total chromium

2

0.07

Copper

1

0.17

Zinc

5

0.14

Fluorine

8

0.2

Boron

10

4.3

Item measured■No complaints■PRTR Data
Substance nameAmounthandledVolume moved

Volume emitted
Into the air

Into bodies of water Into the ground

Volume moved
via sewers

Volume moved
as wasteVolumerecycled

Total removed Total consumed(processed)(products)

Ethylbenzene

7,173

5,738

0

0

0

861

143

0

Xylene12,805

10,240

0

0

0

1,540

256

0

768

Chromium and trivalentchromium compounds

8,575

0

69

0

0

6,792

0

0

1,715

Hexavalent chromium compounds

8,575

0

0

0

0

0

0

8,575

0

Copper water-soluble salts(excluding complex salts)

4,550

0

46

0

0

3,413

0

0

1,092

Toluene49,25039,293

0

0

0

6,017

1,002

0

2,938

Nickel metals

79,780

0

0

0

0

0

0

79,7800

Nickel compounds

85,260

0

17

0

0

11,0670074,177Bis (2-ethylhexyl) phthalate

5,487

8

0

0

0

385

0

0

5,094

Boric acid and its compounds

1,294

0

13

0

0

970

0

0

310

430

TOYODA GOSEI REPORT 2009

Environmental Data
】 • April, 2008 to March, 2009【

Period【Air】 • Units are as follows: NOx = ppm, PM (particulate matter) = mg/Nm3 • ND: below the minimum determination limit (not detected)

【

Water

】 • Units are all in mg/L except for pH • pH: hydrogen ion concentration • BOD: Biochemical Oxygen Demand • SS: concentration of suspended solids in water• Values shown in the results column are averages of the results of the measurements.

• ND: below the minimum determination limit (not detected) • Values shown in the results column are averages of the results of the measurements.

【 Groundwater 】 • Units are all in mg/L • ND: below the minimum determination limit (not detected).
【 PRTR* Data 】 • Units are in kg *Values less than 1kg are rounded up if ≥0.5 and down if 0.5. There are some cases in which values for total volume and volume handled are not in agreement.

*Pollutant Release and Transfer Register (the registration system monitoring emissions of substances that pollute the environment and moves/transfers of them)

Bisai Plant■Air (Air Pollution Control Law, prefectural regulations, etc.)

40 Higashishimoshiro,
Meichi, Ichinomiya,
Aichi, Japan
494-8502

Dust

Main Products

NOx• Interior and exterior parts• Safety system products■Water (Sewerage Law, prefectural regulations, etc.)
Item measured

Regulation value

ResultBoilers (heavy oil)

0.3

0.004

pH

Boilers (gas)

0.05

0.003

Co-generation (gas)0.05

Boilers (heavy oil)180

Boilers (gas)

150

67

Co-generation (gas)

600

110

Item measured■No violations of laws, etc.

Regulation value

Result5.7~8.7

6.9

BOD (Biochemical Oxygen Demand)

300

26.8

ND

SS

300

6.3

78

Oil content

30

0.3

■No complaints■PRTR Data

Seto Plant
141 Sosaku-cho,
Seto, Aichi, Japan
489-0843

Volume emitted

AmounthandledInto the air

Ethylbenzene

14,204

11,361

0

Xylene19,65015,7200

Toluene62,59050,1080

Substance nameVolume moved

0

0

1,706

284

0

852

0

0

2,358

393

0

1,179

0

0

7,491

1,248

0

3,743

■Water (Water Pollution Control Law, prefectural regulations, etc.)

Regulation value

ResultItem measured

Regulation value

Result5.8~8.6

7.6

BOD (Biochemical Oxygen Demand)

20

1.6

SS

20

0.2

Total nitrogen

10

1.5

Total phosphorus

4

0.1

Dust

Boilers (kerosene)

0.2

ND

pH

NOx

Boilers (kerosene)

150

83

Main Products• Interior and exterior parts■No violations of laws, etc.

Total removed Total consumed(processed)(products)

Volume moved
as waste■Air (Air Pollution Control Law, prefectural regulations, etc.)
Item measured

Volumerecycled

Volume moved
via sewers

Into bodies of water Into the ground■No complaints■PRTR Data
Substance name

Kanagawa Plant
19-5 Suzukawa,
Isehara, Kanagawa,Japan 259-1146
Main Products• Interior and exterior parts• Functional parts

AmounthandledVolume emitted
Into the air

Volume moved

Into bodies of water Into the ground

Volume moved
via sewers

Volume moved
as wasteVolumerecycled

Total removed Total consumed(processed)(products)

Ethylbenzene

1,064

855

0

0

0

124

21

0

Xylene

1,332

1,070

0

0

0

155

27

0

64
80

Toluene

2,634

2,116

0

0

0

307

53

0

158

AmounthandledInto the air

1,990

1,630

■PRTR Data
Substance name
TolueneVolume emitted

Volume moved

Into bodies of water Into the ground00Volume moved
via sewers

Volume moved
as waste0247

Volumerecycled

28

Total removed Total consumed(processed)(products)

085

Kitakyushu Plant
1-2 Kitahoraoka Maeda,
Yahatahigashi,
Kitakyushu, Fukuoka,
Japan 805-0058■PRTRデータ
Volume emitted

Volume moved
moved Volume moved
Into bodies of water Into the ground Volume
via sewers
as wasteAmounthandledInto the air

Xylene

1,279

1,011

0

0

0

166

26

0

77

Toluene

1,773

1,121

0

0

0

602

13

0

38

Substance nameVolumerecycled

Total removed Total consumed(processed)(products)

Main Products• Interior and exterior parts• Body-sealing products• Functional parts• Safety system products

Fukuoka Plant■No violations of laws, etc.

■Water (Water Pollution Control Law, prefectural regulations, etc.)■No complaints

Item measuredpH

2223-1 Kurahisa,
Miyawaka, Fukuoka,
Japan 823-0017
Main Products• Interior and exterior parts• Functional parts• Safety system products

Regulation value

Result5.8~8.6

7.4

BOD (Biochemical Oxygen Demand)

10

1.0

SS

25

ND

Oil content

2

ND■PRTR Data

Saga Plant
9966-9 Kawako,
Wakaki, Takeo,
Saga, Japan 843-0151

Volume emitted

AmounthandledInto the air

Xylene

1,708

1,372

0

Toluene

4,607

3,681

0

Substance nameVolume moved

Regulation value

0

0

199

34

0

103

0

0

562

91

0

274

■Water (Water Pollution Control Law, prefectural regulations, etc.)
Item measured

Dust

Boilers (kerosene)

0.1

0.001

NOx

Boilers (kerosene)

150

42

■No violations of laws, etc.

Regulation value

Result5.8~8.6

6.8

BOD (Biochemical Oxygen Demand)

20

9.1

SS

50

4.3

Oil content

5

0.4

ResultpH

Main Products• Optoelectronic Products• General Industry Products

Total removed Total consumed(processed)(products)

Volume moved
as waste■Air (Air Pollution Control Law, prefectural regulations, etc.)
Item measured

Volumerecycled

Volume moved
via sewers

Into bodies of water Into the ground■No complaints■PRTR Data

The Former
Nagoya Plant
1-23-13 Kikui, Nishi,
Nagoya, Aichi, Japan
451-0044

Volume emitted

Volume moved

AmounthandledInto the air

Xylene

2,066

1,656

0

0

0

245

41

0

124

Toluene

8,626

6,907

0

0

0

1,029

173

0

518

Substance name

Into bodies of water Into the ground■Groundwater
Item measured

Regulation value

ResultCis-1,2-Dichloroethylene

0.04

ND~0.009**Refer to Toyoda Gosei Report P.37

Volume moved
via sewers

Volume moved
as wasteVolumerecycled

Total removed Total consumed(processed)(products)

TOYODA GOSEI REPORT 2009

Environmental Data

Resource Input and Output to the Environment in Business Activities in ﬁscal 2008

INPUT

Business activities

Challenges

54,926t

Development DesignResin29,833t

Rubber(rubber sheet)

25,093t● Improve the eﬃciency of gas mileage● Develop parts for hybrids and fuel-cellvehicles as well as parts that can be usedwith bio-energy● Recycling techniques and plans● Abolish the use of banned substances, andreduce the use of VOC*3 in car interiors

Total Material Input

Excluding purchased parts, metal and liquid

Total energy input

Products
Interior and exterior parts
Body sealing products
Functional parts
Safety system products
Optoelectronic products
General Industry Products

3,240,000GJ*1
Emitted into the atmosphere

Purchased electricity: 1,690,000GJCity gas:

Procurement

1,350,000GJ

LPG:

50,000GJ

Heavy oil:

130,000GJ

Kerosene:

20,000GJ● Achieve complete control over the use of
substances that have an environmental
impact, including in delivered parts, rawmaterials, and production facilities.

Production
Water resource input

OUTPUT

1,990,000m3● Reduction of CO2 emissions● Reduction of environmentally harmful
substances● Reduction of waste and materials discarded● Promote the recycling of materials

Industrial water: 910,000m3
Clean water:

340,000m3

Underground water: 740,000m3

PRTR*2 substances usage

Transportation

685t● Reduce CO2 emissions by making
improvements in transportation● Reduction of packaging materials, andimprovement of reuse rate

CO2:117,000t-CO2
SOx*4:
6t
NOx*5:
79t
Dust:
2t
Volume of substances subject to PRTR: 246t

Waste discharge
0t
Landﬁll waste:
15t
Incinerated waste:
10,149t
Industrial waste:
390t
General waste:
For-proﬁt disposal by sale: 6,168t
Volume of substances subject to PRTR: 139t

Waste Water
Total waste water: 1,300,000m3
Volume of substances subject to PRTR: 0.1t

Use
● Improvement of fuel economy● Reduction of environmentally harmful
substances

Recycling Reuse● Improvement of recyclability of used
vehicle parts*1 Gigajoule (1,000,000,000 joules)*2 Pollutant Release and Transfer Register*3 Volatile Organic Compounds*4 Sulfur Oxide*5 Nitrogen Oxide

Environmental Reporting Guidelines (Fiscal 2007 Version)and the corresponding cross referenced pages
Guideline items

Main corresponding pages

Basic items
Message from the president
Basic requirements for the report
Business conditions
General overview of the environmental report
Material balance in Toyoda Gosei’s business activities

Current situation of the conservation of biodiversity and the sustainable use of biological resources

Current situation with environmental communication
Current situation of environment-related social contribution activities
Current situation of products/services to reduce environmental impacts

Main corresponding pages

Environmental impact of Toyoda Gosei’s business activities and current situation with commitments for environmental impact reduction

P3-4
P1
P7-11
P3-4, 25-32, 37
Refer to our homepage

Current situation of environmental administration such as environmental management
Current situation of environmental management
Current situation of compliance with environmental regulations
Environmental accounting information
Current situation of supply chain management
Current situation of green purchasing/procurement
Current situation with R&D of DfE etc. for new environmentally-friendly technologies
Current situation with environmentally-friendly transportation

Guideline items

P25, 32-36
P37, Refer to our homepage
P36
P22, 32-34
P22
P28-32, 35
P29-30
P36
P21
P23
P28-32, 35

Total energy input and measures for its reduction
Total material input and measures for its reduction
Water resource input and measures for its reduction
Quantity of recycled and reused materials within the operational area
Total production quantity and total product sales
Emission of greenhouse gases and measures for their reduction
Air pollution and life environment loads and measures for their reduction
Emission and transference of chemical substances and measures for their reduction
Total waste discharge and total ﬁnal waste disposal, and measures for their reduction

Total water discharge and measures for its reduction

P28, Refer to our homepage
P30, Refer to our homepage
Refer to our homepage
P30, Refer to our homepage
P7-11, 39
P28, Refer to our homepage
P37, Refer to our homepage
P31-32, 37, Refer to our homepage
P30,37, Refer to our homepage
P31, Refer to our homepage

Current related situation between environmental consideration and management
Current related situation between environmental consideration and management

P25-27

Current situation of Toyoda Gosei’s social activities
Current situation of Toyoda Gosei’s social activities

P12-24