Message from the President

1

Corporate profile

2

Consideration for the environment
Corporate philosophy

Message from the President

The history of our environmental protection activities

Environmental principle

4

We, the citizens of this earth, have sometimes wasted its pure water, clean air

Declaration for the environmentand rich resources, taking them for granted. But resources are now rapidly

Environment preservation policy

running out and the burden on the environment is exceeding its self-purification

Action schedule for environment

Environment management systemcapabilities. It is as if the earth was sounding an alarm by showing symptoms of

6crises such as depletion of the ozone layer, global warming, and extinction ofOrganization

species.

ISO 14001 certification
System audit
Our system for compliance with environment-related regulations

In order to protect and restore the global environment, both manufacturers andPreventing pollution in the air, soil and water 8particular, corporate citizens must assume the responsibility of playing a key

consumers must make a serious effort from their respective positions. In

Building a control system for dangerous and harmful substancesrole.

Full abolishment of chlorinated organic solvents

Since most of our company's products are parts, it is more difficult to recognize

Status of handling PCB

Promoting energy saving

their effect on the environment compared with final products. But we do know
10that our parts are contributing significantly to the evolution of environmentally

Energy-saving promotion activities

friendly cars and electronic equipment, making us proud to be engaged in the

Reduction of quantity of energy usedpreservation and improvement of the global environment. In 1974, we

Examplesestablished a division responsible for environmental affairs. Since then we have

Reduction of CO2

Reduction and good use of waste

been complying with not only standards required by law but also our self-control
12

standards. We have obtained ISO 14001 certification, an international standard

Achievements in 2001

for environmental management systems, first at our head office/factory in 1999,

Zero-emission goals for and after 2002

and then at four factories collectively in 2000. Our affiliated companies are

Goals and achievements in main challenges in 2001

currently preparing to acquire the same certification.

Product development which considerd environment 14

Our efforts in 2001 based on the Environmental Action Schedule, including

Iridium Plugs

energy saving and reduction of wastes and substances posing a burden on the

Air Quality Sensors

environment, produced positive results, although some exacting conditions do

Packages for Crystal Devices and SAW Filters

remain. Through our products we are also contributing to resource conservation

Antenna Switch Modules

by producing smaller and lighter plugs. The hard work we are carrying out in our

Bio ceramics

factories to reduce and even eliminate harmful substances is showing steadyCutting Tools

Education and awareness activities

progress. The functions of some of our products themselves directly protect the18

environment, such as our sensors which are aimed at cleaner exhaust gas andPromotinon of environmental education

improved fuel consumption. We have also taken steps to save resources andEnlightenment activities

provide lower electricity consumption in producing semiconductor components

Consideration for environment of local communities 19

such as IC packages and filters used for PCs and mobile phones, which are

Local cleaning activities

becoming increasingly small-sized and highly-integrated year by year.

Participating in the Environmental Partnership Organizing Club (EPOC)

Environmental accounting

20

Green Procurement

21

We hope this report has given you an idea of our hard work and achievements
in 2001. Environmental preservation activities depend on each and every
employee being motivated. We intend to continue contributing to society by

Requests to partners/suppliers

conducting education and enlightenment through environmental conferences,

Encouraging use of “eco” stationery

our in-house magazine and other activities. We welcome your comments on thisConsideration for the environment with packing materials for our products

report.

Environment measurement data by factory 22
Environmental preservation achievements

Work safety and hygiene

Scope of this Report

24

Safety and hygiene
Handling chemical substances kind to human beings via an MSDS

Conclusion

25

This Report shows you wide variety of efforts
by NGK SPARK PLUG CO., LTD to get rid ofenvironmental burden during the fiscal year
2001 (April 2001 - March 2002).
The articles also introduce our affiliatedcompanies obtaining the ISO 14001
authorization.

Shigenobu Kanagawa, PresidentCorporate profile as of June 30, 2002

Consideration for the environment

Company Name: NGK Spark Plug Co., Ltd.
Head Office:14-18 Takatsuji-cho, Mizuho-ku, Nagoya,
Aichi Pref.
Founded:
October 26, 1936
Capital:47,869.27 million yen
Business:①Manufacturing and selling spark plugs
and related products for internal- combustion
engines②Manufacturing and selling new ceramics
and applicable products
Number of Employees:
5,552
Head Office/Factory
1,056
Komaki Factory
2,905
Kagoshima-Miyanojo Factory
555
Ise Factory
445
Others591

Technology supporting environmentally friendly
products and the future of the earth
Seeking greater performance, comfort and cleanliness, our technology is always evolving inconsideration of environmentally friendly production and the future of the earth.
Our wish is to deliver products that will satisfy our customers, while handing down thisbeautiful earth to following generations.
Looking one step ahead and never compromising, we are constantly facing the challenges
of innovation.
Our aim has been, and will continue to be, the creation of new value.

●Progress in sales●Products supporting the world
Spark Plugs
These are essential parts for automobile
engines. NGK Spark Plugs have developed
together with the history of the company. We
are now working hard on the design ofenvironmentally friendly products that
ensure stable efficiency, cleaner exhaustgas and energy conservation.

Sensors
We are developing and applying suitablesensors that help to conserve nature bymaking cleaner exhaust gas, saving
resources and combatting global warming.
Of course we also provide sensors toprotect the comfort of our life.

Semiconductor Components
Our ceramic and organic packages meet thedemands of semiconductor componentsthat can support the evolution of the IT
industry, while protecting the environment
with their higher density, higher speed andsmaller sizes.

The history of ourenvironmental
protection activities

Corporate philosophy
Always be a propositional-type company to transmit
new values to the world.

1974. 02

By bridging people with technology and maintaining globalscale thoughts and views, we will always seek what weshould be.

SloganWith established trust and confidence inside and outside thecompany, we aim to contribute to the people of the world bycreating and offering new values for the future.

Established a Safety and Sanitation
Committee and an Environment
Committee

1974. 03

Komaki Factory entered into a pollution
prevention agreement with Komaki City

1980. 04

Kagoshima-Miyanojo Factory enteredinto a pollution prevention agreementwith Miyanojo Town
Established an Energy Conservation
Expert Committee

Electric Components
Mobile phones are already necessities intoday's world. Working inside them are ourdielectric filters and antennas, essential for
sending and receiving radio waves. Our
enduring challenge is to achieve evenclearer reception and lighter weight.

1980. 11

Introduced a closed-system drainage
facility for plating processes in
Kagoshima- Miyanojo Factory

1993. 11

Ise Factory entered into a pollution
prevention agreement with Ise City

1994. 04

Introduced a fully-closed-systemdrainage facility for production-use waterin Ise Factory

1999. 04

Issued an "Environmental Declaration"

1999. 08

Head Office/Factory obtained ISO
14001 certification

1999. 10

Established a Wastes Expert
Conference, Green Procurement Expert
Conference and Chemical Materials
Expert Conference

2000. 09

Issued the first edition of "ECOREPORT"

2000. 12The entire company obtained ISO 14001
integrated certification

2001. 06

Held the first Environment Congress

Cutting Tools
Our cutting tools are developed with ourown special technology. The Ceramic
Series are used for high-speed cutting ofcast iron and heat resistant alloys, and the
Cermet Series are used for semi-finishingand finishing of steel. All our cutting tools
are highly evaluated by users.

Fine Ceramics
We provide a diversity of products thatmake use of the characteristics of new
ceramics. The practical applications range
from ultra-hard bearings to various
artificial bones utilizing apatite hydroxideand zirconia, materials that are compatible
with the human body.

2

Established a Safety and Environment
Section (present Environment and
Safety Dept.)

Management Policy

Commitment

Action Guideline

We offer a working environment
in which each one of us isencouraged to make full use of
his or her personality andcapability. With all our power weare dedicated to pursue
management based on trust andconfidence.

With full use of the most suitable
technology and our accumulated
experience, we continue striving
to offer new values to people of
the world.

Ever onward!
Always mindful of what is the best
course, we swiftly put it into action.

made in November 1996

3

Environmental principle

Environmental principle

We believe corporate activities and environment
protection should be connected and both working
healthily.
As one of our key issues to live up to our principle of "being a propositional-type company always giving
new value to the world", we are place great importance on the preservation of the global environment.
Under the "NGK Spark Plug Co., Ltd. Environmental Declaration" made in 1999, we will rotate the PDCA
cycle in our environment management system to promote continuous improvement.

We make an Environment Action Schedule every year in order to put our plans under the environment
policy into actual practice. The table below shows our goals and achievements in 2001, and outlines the
Action Schedule for and after 2002. Please see the related pages for details of each plan.

Action schedule for environment (made in April 2001)

Declaration for the environment (made in April 1999)
Item

We aim to create new values through all our corporate activities such as development,
manufacture and sales of NGK spark plugs and NTK new ceramics products as a company
protecting the global environment and living in symbiosis with society.
In order to achieve this goal, we have compiled an environment action schedule based on ourenvironment policy and will promote management that can be continuously developed and constantcorporate activities in consideration of the preservation of the environment.

Environment preservation policy (revised in April 2000)
1 To accurately grasp the effect ofcorporate activity on the environment,
set an environmental objectives andReduction of paper used for copying
targets. These should be reviewed
Promoting energy saving
Reduction goal in 2002:
regularly for a continual improvement
We combat global warming by reducing▲25% from the previous year
the amount of CO2 discharged.
of the Environmental Management
Direct operations: Original unit ▲1%/year
System (EMS) and performance forOverhead: Total quantity of discharge
environmental preservation.
Ceramics-related business▲1%/year
2 We will abide by laws, regulations,
Our new ceramics play active
Consideration for the environment
roles in a wide variety ofagreements and other demands we haveof local communities
industries and environmentActively participate in cleaning activities
agreed to concerning environmental
related areas.
around factories and environmental
preservation.
protection
activities
in
local
communities
Building environment-management
3 Priorities in environmental measuressystems (ISO 14001)
a. We will endeavor to prevent
2000 All factories obtained
pollution in the air, soil and water.
integrated certificationb. We will promote energy saving.
2003 Expanding to affiliated Automobile-related businesscompanies
c. In order to use resources efficiently,
Plugs should realize highest
Nittoku Environment Congress 2002
Chlorinated organic solvents
combustion efficiency.
we will promote reusing and
We promote employees’ motivation
2002: Full abolishment in all the factories
Sensors should make exhaust
making good use of wastes.※
under the theme “Everyone
2004: Full abolishment in Group A
gas cleaner
get closer to the environment”.
d. We will endeavor to design andaffiliated companies
develop products with concern for
the environment.
Zero-emission to be achieved in:e. We will have high concern for the2002 at Miyanojo Factory
environment of the local community.
Overseas offices/factories with
2003 at Head Office/Factory
ISO 14001 certification
4 In order to achieve this Environment
2004 at Komaki and Ise Factories
Communication-related business
NGK Europe
Policy, we will make sure our2005 at affiliated companies
NGK U.S.A. West Virginia
Through higher integration andemployees know of this policy, andNGK
U.S.A.
Irvinesmaller-sizing, we contribute to
NGK Brazil Cockcala
conduct environmental education as
the continual evolution of energy
NGK U.K.
well as publicity to improve the level ofand resource conservation.
recognition among our employees forenvironmental preservation. We will
also ask related companies for theirunderstanding and cooperation, as
Our 4 regions
well as disclosing information outside
Overseas Group affiliated companies
Head Officethe company.
Komaki
Miyanojo
Ise
Ceramic Sensors
Nittoku Transport
Nittoku Alfa Service

Production and sales network developed
across the 5 continents of the world
Group A affiliated companies

Iijima Ceramic
Nakatsugawa Ceramic
Kani Ceramic
Ohguchi Seiki
Nanse Ceramic※Updated from “recycling and reusing” into “making gooduse” in the 2000 verision.

Group B affiliated companies
Kamioka Ceramic
Nittoku Manufacturing
Nichiwa Machinery
Tono Ceramic

Environmental
Management
SystemEnvironment Action Schedule
for and after 2002

Relatedpages

After the start of preparationsin September and October
2001, the system will begin
operation in April 2002

To build and operate EMS
throughout the company basedon ISO 14001.
To obtain certification in majordomestic affiliated companies by
2003.

6、7

Steps for 2001 have beentaken for further review on
their effects

To perform thorough control and reductionof dangerous and harmful substances.
To perform thorough control and reductionof discharge and movement of substances
posing a burden on the environment(particularly those applicable to PRTR
Law).

Action Schedule for 2001

Achievements in 2001

To start to prepare for certificationin 2002 at five domestic affiliatedcompanies

To reduce exhaust emission of all
target gases by 20% (original unit)
by 2005

Prevention ofpollution in the air,soil and water

Evalu
ation

8、9

Head Office/Factory:Facilities
To prepare for full abolishment ofchlorinated organic solvents by theend of 2002

To reduce energy consumption by
Promoting energy
1% (original unit, compared tosaving2000)

introduced in March 2002
Komaki:Full abolishment
achieved in May 2001
Miyanojo:Full abolishment
achieved in February 2002
Ise:Full abolishment achieved in
September 2001

To fully abolish the use ofchlorinated organic solvents by
the end of 2002.
To reduce the use of alternativesolvents.

Target reached: Miyanojo
Target not reached: Head
Office, Komaki and Ise

To reduce total CO2 discharge per
original unit in direct production
division by 1%/year.
（※1） To reduce total CO2 discharge inother divisions by 1%/year.
（※2）

10、11

To promote reduction and gooduse of wastes.
To achieve zero emission in all（※3） domestic factories by 2004 .
（※4）

12、13

Reduction ofwaste andpromotingrecycling

To achieve these rates Head Office/
Factory: 20%
in buried/combusted
Komaki:55%
garbage (compared toMiyanojo:40%
1999)
Ise: 70%

Head Office/Factory: 9.1%
Komaki: 71.2%
Miyanojo: 54.6%
Ise: 70.0%

Products
development withconsideration for
the environment

To review the raw materials for
products and packaging to reducethe burden on the environment

In progress according to
the Schedule （※5）

To advance product development
by evaluating the environmental
burden and considering LCAs that
contribute to environmental
preservation.

14〜17

Consideration for
the environmentof the local
community

To implement cleaning activities
around factories at least twice a year

Performed at least twice inthe year, participated in
activities conducted bygovernment agencies

To promote coexistence with society
through environmental conservation.
To participate in local community
environmental conservation activities.

19※1： Although Miyanojo reached its target, some development-related divisions at the other 3 factories could not save enough energy to balance a decrease insales, resulting in the failure of the company as a whole to reach its target.
※2： The basis for the energy-saving action schedule for 2002 will be changed to CO2-based targets (from petroleum-based targets in 2001). In order to makefurther progress and prepare for a change of standards to reduce total CO2 discharge, indirectly related divisions such as office areas will have targets to
reduce total CO2 discharge in 2002.
※3： Although the Head Factory could not reach its target, the other 3 factories and the company as a whole succeeded.
※4： The time line to achieve zero emission in the four domestic factories will be targeted in 2004, which is one year earlier. The five domestic affiliated companies
to obtain certification this year will have action targets of achieving zero emission by 2005.
※5： Some item numbers of spark plugs have completed small-sized and lightened designs and are currently in commercial production. We have determined
substances to replace those posing a burden on the environment (hexachromium and lead).
Achieved

Partly achieved

Not achieved

Based on the Environment Action Schedule shown above, each organization sets and exercises its own
specific objectives and targets.
※This picture is reprinted from the 2002 environment poster for in-house enlightenment.

5

Environment management system
Environment management system

The entire our group is addressing environmental
issues by setting unified goals and taking them asimportant management indicators.
System audit

The environment is a global-scale issue, and our behavior as corporate citizens and human beings is inquestion today. We regards environmental issues as challenges to be addressed by the entire group,
which is why we are expanding our environmental management system to our domestic affiliatedcompanies. Meanwhile, our affiliated companies overseas are pushing to obtain ISO 14001 certification.
We will continue to promote its activities toward the fulfillment of ever higher goals.

Under the ISO environmental management system, we conduct an in-house audit once a year andundergo a third-party audit every year to enhance our system. In-house audits are conducted according
to our In-house Audit Checklists by 200 registered auditors elected within the company, who are
divided into two-person teams. These auditors receive skill-maintenance training every year to maintainand enhance their auditing ability.
The numbers of problems found in the entire four regions in 2001 were two in third-party audits and 90
in in-house audits. The main problems were that some divisions that changed their production
processes did not adequately examine environmental aspects or evaluate the impact on theenvironment. We have already taken corrective measures including company-wide expansion.

Organization
For the purpose of promoting cross-organizational activities to preserve the global environment, weestablished a division in 1974 responsible for environment-related issues. At present we have an
Environment Committee, which is a supervising organization responsible for preserving the global
environment, as well as sub organizations called Expert Committees and Expert Conferences at thecompanyﾕs center and various sites, which are responsible for respective business fields. Within thisstructure, every department is engaged in environmental conservation activities to accomplish theenvironmental plans and targets in accordance with our Environment Policy.
Environment Supervising
Director

Central Environment
Committee

Central Energy Saving Expert
Committee

Environment Management
Director

Regions

Expert Conferences

Environment & Safety
Department (secretariat ofeach committee)

Factories

President

In-house audit

Most of the issues to be addressed under the Environment Action Schedule are subject toenvironment-related regulations. We have people legally qualified in these matters in each region tocomply with such regulations. Please see pages 22-23 for this year's state of compliance.

Certifying organization

Numbers in parentheses ( ) are legal requirements:

August 1999

Skill-maintenance training for in-house auditors

Our system for compliance with environmentrelated regulations■ISO 14001 certification status
Date of certification

200

Third-party audit

We are pressing to fulfil the requirements for ISO 14001 certification, an international standard forenvironmental management systems (EMS), in order to strengthen our management of environmental
preservation activities and enhance the transparency of these activities by disclosing them to the public.
Our Head Office/Factory was the first to obtain certification in August 1999. The other three factories, Komaki,
Kagoshima-Miyanojo and Ise, followed in December 2000, along with general certification for the whole
company based on our common environment policy, manuals and standards.
Among our affiliated companies, three in Japan and five overseas have already obtained certification, and theother nine companies in Japan are aiming to obtain certification by 2003 to increase the number of certifiiedsites within our group.

Office/Factory

ISO 14001 In-house

Wastes Expert Committee

ISO 14001 certification

Head Office/Factory

5

Energy Saving Expert
Committee

Environment Committee※ The regions consist of Head Office/Factory, Komaki, Miyanojo, Iseand affiliated companies

Head Office/Factory Region

ISO 14001 Deputy

Environmental Management System■Environment
Activities
Promoting
Organization■Numbers of ISO 14001 auditors

December 2000

Miyanojo Region

Kagoshima-Miyanojo Factory

December 2000

Ise Factory

December 2000

Ise Region

Nittoku Alfa Service Co., Ltd.

August 1999

Ceramic Sensors Co., Ltd.

December 2000

Nittoku Transport Co., Ltd.

TUVRHEINLAND JAPANw

December 2000

I

D

Affiliated companies Iijima Ceramic Co., Ltd. Ohguchi Seiki Co., Ltd.
Expected toin Japanobtain certification
Nakatsugawa Ceramic Co., Ltd.
in 2002
Nansei Ceramic Co., Ltd. Kani Ceramic Co., Ltd.
Expected toobtain certification
Nittoku Manufacturing Co., Ltd. Tono Ceramic Co., Ltd.
in 2003
July 2000
NGK USA Co., Ltd. WV Factory※ww

Head Office. t uv. co

Berlin:009104823

7

国際的な第3者認証機関TUVラインランドの「TUVdotCOM」に当社の認証情報が登録されました。
ID：0091048237

6

NGK Spark Plugs (U.K.) Ltd.

August 2001
December 2001

Pollution
prevention
manager

Komaki

Kagoshima-Miyanojo

Ise

Total

Air

9（2）

18（2）

2（2）

1（1）

30（7）

Water

11（0）

26（4）

10（2）

2（0）

49（6）

Noise and vibration

23（4）

21（4）

11（2）

1（1）

56（11）

5（0）

7（0）

0（0）

3（0）

15（0）

Heat

3（0）

6（1）

3（1）

0（0）

12（2）

Electricity

Working environment examiner
Energy manager

5（1）

1（1）

4（1）

2（1）

12（4）

Specially controlled industrial waste manager

7（1）

7（1）

5（1）

3（1）

22（4）

No. of breaches, penalties and lawsuits

0

0

0

0

0

No. of requests or claims from interested parties

0

1

0

0

1

http：//www.tuv.com:

Kamioka Ceramic Co., Ltd. Nichiwa Machinery Co., Ltd.

Affiliated companies NGK USA Co., Ltd. IRV Factory
overseas (certified NGK Spark Plug Industries Europe S.A.
companies only)
Special Pottery Europe S.A.

No. of qualified people

Komaki Factorym

Komaki Region

TUV RHEINLAND OFNORTH AMERICA
ABS QUALITY EVALUTION INC.

May 2000

AFAQ

January 2002

BSI（British Standard Institute）※ Sensor USA. Corp. WV Factory changed its name to NGK USA Co., Ltd. WV Factory as a result of a reorganization of affiliated companies in the USA

7

Preventing pollution in the air, soil and water
Preventing pollution in the air, soil and water

We will endeavor to reduce and properly control
exhaust and discharge of substances that pose aburden on the environment, and to promote theirreplacement by safer substances.
We are making every effort to ensure proper control and reduction of harmful substances and theirreplacement by safer substances, by setting self-restriction standards for handling substances that are
dangerous or harmful to the natural environment, including the air, soil and water, as well as the working
environment, including safety and sanitation. For example, we endeavor to replace, reduce or control thedischarge of high-risk substances such as hexachromium, lead compounds and chlorinated organic solvents.

■INPUT-OUTPUT diagram of PRTR substances (2001)
Air
22,790（4.1％）

Unit：kg

Products
288,190（52.2％）

INPUT

552,218（100％）OUTPUT
Disposal by sale
20,465（3.7％）
Waste
62,628（11.3％）

Building a control system for dangerous andharmful substances
We are furthering the control of chemical substances, replacement with safer substances and reductionof exhaust and discharge, by building a computer system to calculate standards for handling dangerous
and harmful substances and quantities of substances posing a burden on the environment (PRTR
substances). In addition, we have an in-house network that lets us browse up-to-date information on
MSDS and makes it easy to check regulations and in-house rules associated with environment andsafety. Defining substances that should be prohibited, reduced and controlled, our Chemical Substances
Expert Committee preaches replacement with safer substances and proper handling of substances. The
following table shows PRTR substances used in 2001, which decreased to 22 substances (from 23 in
the previous year). Among them chlorinated organic solvents and hexachromium show sharp decrease.

Quantity of removal/disposal
158,067（28.0％）

Full abolishment of chlorinated organic solvents
kg/month
Head Office/Factory

14,000

Komaki Factory

12,000■Results of the PRTR survey: All factories (April 2001 - March 2002) ※1
Regu
latory Chemical SubstancesNo.

Handling
Offices/Fact
ories （※2）

Zinc aqueous compound H・K・M

Air

Water

Quantity of
Quantity
movement tohandled:publicDecompo Intermediate Reclamati
Soil Products Supply Incineration sition disposal
Recycling drainage this yearon

Quantity moved as
waste

Quantity
Eval
handled:uati
previous
on
year

8

0

29,472

0

0

0

3,596

0

0

0.1

33,077

29,844

326

0

0

0

0

0

2,790

3

0

0

0

3,119

2,520

H・K
and trivalent
68 Chromium
H・K・M
chromium compounds
69 Hexachromium compounds H・M

1,784

0

0

0

0

0

22,958

7,344

0

17

0

32,10339,657

0

0

0

1,126

804

0

62

581

12

1,562

0

4,147

2,864

0

0

0

33

0

0

2,080

0

0

0

0

2,113

57,16063 Xylene

100 Cobalt and its compounds

H

108 Inorganic cyanogen compounds H・K・M

0

0

0

1,943

256

0

0

45

110

0

0

0

2,861

1,323

0

5,037

31

0

16

0

2,370

3,304

105

0

9,357

7,705
1,500

144 Dichloropentafluoropropane

H

3,600

0

0

0

0

0

0

0

0

0

0

3,600

200 Tetrachloroethlene

H

729

0

0

0

0

0

0

0

0

3,529

0

4,258

4,752

K

0

28

0

22,940

0

0

0

1,403

4

0

0

24,37526,288Bronze aqueous sodium chloride
207 (except complex chloride)

211 Trichloroethylene

H・K・M・I

10,867

0

0

0

2,346

0

0

0

0

1,507

0

14,72061,048227 Toluene

H・K・I

4,434

0

0

0

0

0

116,783

260

0

186

0

121,664

120,276

230 Lead and its compounds H・K・I

0

0

0

63,404

5,333

0

0

828

830

20,527

090,922131,010231 Nickel

H・M

0

0

0

151,724

10,309

0

0

0

0

0

0

162,033

180,104

31

0

6,413

10

0

0

2,402

117

0

0

8,974

12,445

7,162

0

0

0

0

7,166

6,612
11,254K

0299 Benzene

H・K

4

0

0

0

0

0

304 Boron and its compounds

K

883

12

0

7,015

0

0

0

406

116

17

0

8,448

309 ether

Poly(oxyethylene) nonylphenol

K

0

0

0

0

0

0

77

7,515

0

0

0

7,592

−

310 Formaldehyde

K

6

0

0

1

21

0

34

3,358

0

0

0

3,420

3,071

311 Manganese and its compounds

232 Nickel compounds

K

0

0

0

21

0

0

0

5,551

2

4

0

5,578

3,277

314 Methacrylic acid

K

157

0

0

0

0

0

1,083

315

2

0

0

1,557

−

Molybdenum and its
346 compounds

K

Total

0

0

0

1,237

63

0

0

71

256

0

0

1,627

2,615

22,79078

0288,190

20,4650

158,067

33,7081,450

27,4700.1

552,218

707,306

Ise Factory

10,000
8,000

6,319

6,000

1,026

4,000
1,753

1,008

2,000
2,519
0

2,240

1999

1,756

574 171
731 451

2000

2001

120
2002

0
2003

(expected)(expected)

Status of handling PCB
A sign at a warehouse for PCB storage※1：■parts show substances of which more than 5 tons were handled in 2001 and were reported to government agencies as required under PRTR Law.
※2：H stands for Head Factory, K for Komaki Factory, M for Kagoshima-Miyanojo Factory and I for Ise Factory.
Reduced from previous year

8

Same level as previous year

Increased from previous year

(Fiscal year)

Subject to the prohibition of production oftrichloroethane under Section 1.1.1 of the Montreal
Protocol, we completed full abolishment bySeptember 1995 and are carrying out a policy tofully abolish other chlorinated organic solvents
including trichloroethylene by the end of 2002. To
that end, each division is drawing up fullabolishment programs, reporting their progressincluding technical achievements to theEnvironment Committee, and extending theirachievements to related divisions, affiliatedcompanies and subcontractors.
In 2001, we achieved full abolishment at Komaki,
Kagoshima-Miyanojo and Ise factories and 83%
reduction in the company as a whole compared to
1999. The Head Factory is also expected toachieve full abolishment within the first half of 2002.

In July 2001, the Special Measures Law
Concerning Advancement Of Proper Disposal of
Polychlorinated Biphenyl (Special Measures Law
against PCB Waste) took effect. This law requires
the status of PCB storage and disposal to bereported to local governments.
At NGK, high-voltage equipment using PCBs andballast for fluorescent lights containing PCBs havebeen in safe keeping since 1975, under strict
control to prevent leakage. The relevant offices andfactories have now reported their storage status inaccordance with the law.

Inside of a warehouse for PCB storage

9

Prevention of pollution in the air, soil and water

0

H・K

1

40 Ethyl benzene

Kagoshima-Miyanojo Factory

1,027

Unit: kg

Quantity of
Quantity
exhaust/discharge(consumed) removed/disposed

Quantity of
exhaust/discharge

Water
78
（0.01％）

Promoting energy saving
Promoting energy saving

Examples (Ceramic Sensor Corp. in Komaki region)

We will endeavor to make efficient use ofenergy companywide in order to contribute topreservation of the global environment.

In the past, our Project Team for Cost Reduction andStreamlining consisted of Production, Quality Control,
Sensor Technology and Production Engineering Divisions.
In 2000, the Environment Preserving Secretariat participatedin the team to address energy saving to preserve theenvironment. As a result, we reduced energy consumption
in original units by 13.9% in 2000 (for which we received anaward) and 1.1% in 2001. We received the “Japan Central
Region Minister of Economy and Industry Award” in the
Energy Saving and Electricity section in February 2001 forour consistent new ideas and performance.

To reduce the quantity of CO2 emissions, which are a major factor in global warming, and to utilize limited
resources effectively, it is essential that we make more efficient use of energy to reduce the amount used. Morespecifically, we are conducting a number of energy-saving activities ranging from enforced light-out habits ineveryday operations to improved production facility and indoor air conditioning. Starting from 2002, our energysaving goals are defined by CO2-based figures, in order to enhance awareness of energy conservation activities.

Energy-saving promotion activities

Regional Energy Saving Expert
Committees

Comparison with Comparison withthe previous year the previous year
▲13.9%▲1.1%

S/1000pcs.

0.40
0.30
0.20

0.409

0.352

0.348

2000

2001

0.10
0

1999

Hydrogen aging process(Fiscal year)

Effects■Treating plated materials by aging withatmosphere of hydrogen (reduced)

Central and Regional Energy Saving Expert Committees
These committees act under the Environment Committee
to discuss and resolve energy-saving issues and support
the activities of divisions.
● Managing the progress of fiscal energy-saving plans●Emulation and development of successful in-housecases of energy-saving● Regular energy saving patrol in all divisions● Providing information and awareness activities
concerning energy saving■Quantity of energy consumption in original units

After
improvement

Beforeimprovement

Treated quantity per
200 pcs./sheath 400 pcs./sheathsheathBeforeimprovement
After
improvement

20 min/sheath
3 sec.

Achievements

20 min/sheath
6 sec.

Piece time

Double-door cylinder

Double-door cylinder

P.T

kwh/Hrpc/Hr

kwh/1000

6sec.

18.68

600

31.13

3sec.

18.68

1200

15.56

60% of all item numbers improved
to 400 pcs./sheath.

Target: reduction
by 30%, 9.3 kwh

21.79■Energy-saving effect achieved in 2000 by improved treatment
ability in hydrogen aging
Power consumption in original unit（kwh）

Original unit
32
Target（kwh）
30
28
26 Reduced by 30%
24
Reduced by 57%
2220
4 5 6 7 8 9 10 11 12 1 2 3 （a month）

Reduced atmosphere
Emulation anddevelopment of successfulenergy-saving cases

Poster to raise awareness ofenergy saving

Hydrogen furnace

Aging with atmosphere ofhydrogen (reduced)

Reduction of quantity of energy used
Electricity saving by spraying the chillers with water

Effects

Main energy-saving operations● Inverter operation of fans in air conditioning equipment in factories (Head Factory) 60,000 kwh/year● Enabling primary pumps of absorption-type freezers to adjust their flow rate (Komaki Factory) 272,000 kwh/year● Efficient operation of spray driers by combination of multiple units (Komaki Factory)

163,000 kwh/year● Intermittent operation of mixers in tanks for raw materials (Komaki Factory)

127,000 kwh/year
13,000 kwh/year● Abolishment of high-pressure washing by improving products (Ise Factory)

288,000 kwh/year

2Inspecting company : If you do that, silica will cake on thefins of the cooling coils. Silica cannot be removed so the coilfins themselves will become defective. We have never done
this in the past.
3 Supervisor : I recommend the members try it first forthemselves.

■Quantity of energy used (original unit)
Energy original unit = energy consumption / value added manufacturing amount

1.2

4Result : The load factor on the compressor reduced. Silica
did not cake.

Promoting energy saving● Reduction of wattage of mercury-arc lamps by keeping proper illumination

1Circle member : We would like to save electricity by spraying
the cooling equipment with water.

■Electricity reduction effect2000 2 units

68,000kwh／year

2001 12 units

308,000kwh／year

Original unit

Spray nozzle

1.0

Reduction of CO2

0.8
0.6

Energy-saving target for 2002
●Production divisions

0.4

To reduce CO 2 discharge from energy
consumption by 1% in original unit (from theprevious year)

0.2
0.0

1998

1999

2000

2001

(Fiscal year)● Last year the overall energy original unit in four our factories worsened contrary to the decreasing trend until the previous year.
This is because energy reduction rates in the facilities including air conditioning equipment did not keep pace with thedecrease in the value added manufacturing amount.
● We have used the value added manufacturing amount calculated by subtracting the material costs and subcontract processing
costs from the gross sales amount for the calculation of the energy original unit since 1998.

●Other divisions
To reduce CO 2 discharge from energy
consumption by 1% in total quantity (from theprevious year)

All the employees will work together on energy
saving to reach these targets.

■Quantity of CO2 discharge and sales
Quantity of CO2 discharge（tonCO2）

125,000

Sales(hundred million yen)
Quantity of CO2 discharge
Sales (parent only)

100,000

2,000

75,0001,500

50,0001,000

25,000500

001990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001

10

2,500

(Fiscal year)11Reduction and good use of waste
Reduction and good use of waste

If thrown away, it becomes garbage. If divided, it
will become resources. We continue challenging
this view.
We see the issue of garbage as being at the very core of environment activities, and have taken it
seriously since these activities started. The basic way to know about garbage is to separate it: we arepromoting programs to reduce and make good use of garbage based on this idea. In our efforts to achieve
zero emission, we are trying make our activities more fun by using cartoons to explain the overall
procedure from garbage separation to collection.

Achievements in 2001

Goals and achievements in main challenges in 2001
■Example 1: Recycling post-production waste fluid and sludge■Waste in Komaki Factory（t）Started recycling
sludge producedby plating

1,000■Quantity of waste

Recycling rate
（％）

100

800

80

600

60

400

40

Valid usage

200
As we increased production of semiconductor-related products in 2001, the total quantity of waste also
increased by 27% from the previous year. However, our efforts to promote recycling achieved a valid
usage rate of 91%, 3% higher than our target. Meanwhile, the quantity of buried/combusted garbage isdecreasing year by year: it was more than 4,000 tons in 1999, but had fallen to 1,350 tons in 2001, one
third of the original figure.

Started recycling
post-productionwaste fluid

Buried/combusted
Valid usage rate
Targets

20

Goal（110 t )01999 2000 4 5 6 7 8 9 10 11 12 1 2 3(Fiscal year)
Month of 2001 (Fiscal year)

After Komaki Factory increased its
production of semiconductor-related
products as one of its main areas, postproduction waste fluid and sludge also
increased. We have now, however,succeeded in recycling both bycollecting the metal constituent of waste
and processing sludge into materials forroad foundation. Accordingly, in spite of
the increase in total quantity ofdischarge, we have reduced the quantityof buried/combusted waste significantly
more than targeted.

0■Example 2: Introducton of a bio-type waste disposer

Quantity of discharge(t/month)

1,600
1,400
1,200
1,000
800
600
400
200
0

Recycled
Buried/Combusted

1,004

1,117
785

342
1999

200
2000

113
2001

67
2002

KagoshimaMiyanojo/comp
ost type

May, 1997

100

20

Utilizing as manurefor green plants

Komaki/com
post type

July, 2001

280

25

Testing to utilize as
manure for green
plantsIse/dry typeFebruary
2002

73

18

Utilizing as manurefor green plants(expected)

Total

Since manufactured products and waste vary from factory to factory, we set time lines to achieve zeroemission at each one. As the valid usage rates significantly improved at the other three factories

Use of treatedgarbage

Date ofintroduction(Fiscal year)

Zero-emission goals for and after 2002

Weight of Weight after
perishable in-house
treatment
garbageByfactory/type

Fiscal year of 2001

81tons

10tonsReduced by 71 tons

Fiscal year of 2002
(expected)

114tons

16tonsReduced by 98 tons

“Gomitaro”, a bio-type waste disposer in Komaki
Factory

The Kagoshima-Miyanojo Factory introduced a machine in 1997 to treat perishable garbage produced fromthe canteen. This machine was also introduced at our Komaki and Ise Factories in 2001, achieving
reductions of up to 71 tons per year in the whole company. We utilize treated garbage as manure for green
plants at our factories.

excluding the head factory, we reset the targeted year for zero-emission achievement from 2005 to
2004 at Komaki and Ise Factories.

■Example 3: Curtailment of the copy paper use (an example of “reducing”)

as the most desirable, by promoting programs closer to our operations such as improvement of design

Our recycle rate of waste paper is 95%. However, the quantity of paper used in the company in a year
amounts to 80 tons, 18 million sheets of A4 paper: This is equivalent to a surprising 300 sheets of A4
paper per employee being used every month (results from 2000). In 2001, we initiated company-wide
paper reduction, and managed to use 25% less than the previous year. We aim to lower this figure to
25% in 2002 (equivalent to up to 50% less than the quantity used in 2000).

and processing techniques, quality, and yield.
■Target year for zero-emission achievement

Our definition of zero-emission
In our company, zero-emission is defined as the
reduction of combusted/buried waste, including
both industrial and general wastes, to a valid
usage rate of at least 98%. The reason why weregard 98% as the “zero” line is that excessive
energy consumption would be required topursue absolute zero in general garbage suchas cigarette butts, tea leaves and so on.
The valid usage rate applies to a consolidationof “reusing” and “recycling” areas.

Head Office
Fiscal year of 2003

Guidelines for reduction ofphotocopying paper

KomakiFiscal year of 2004

● In-house communication should bemade via computer, not on paper.

Ise
Fiscal year of 2004

● Materials at meetings should be
displayed on a PC or projector, notdistributed on paper.

Kagoshima-Miyanojo
Fiscal year of 2002

■Progress in valid usage rate

Valid usage rate（％）

100
Miyanojo Factory
Head Office/Factory80● When photocopying is necessary,
double-sided copying or using thereverse side of used documents
should be encouraged.
Quantity of
paper used

If we piled up all the
documents we used,
they would reachhalfway up Mt. Fuji.

（kg）

90,00080,00070,00060,00050,00040,00030,00020,00010,000
0

5,088

Ise
Miyanojo

Reduction of waste and promoting recycling

In the future, among the 3 R's (reducing, reusing and recycling) of waste we will focus on reducing

KomakiHead Office

7,363
3,268
6,068
44,66734,26923,444

16,472

2000

2001

2002 (Fiscal year)(expected)

Komaki Factory

60

12

13

Ise Factory

1999

40
2000

2001

2002

2003

2004 (Fiscal year)

Product development which considerd environment
Product development which considerd environment

Technology aims of an eco-friendly
product and the earth.
Although many of our products are small functional parts, the final products can only work properly if eachof these parts performs well. We will continue to promote our development system that aims to help
improve the global environment.

Spark Plug Division● Iridium Plug

Makoto Sugimoto

In general, it is recommended that spark plugs are replaced every
20,000 km in cars and every 10,000km in light vehicles. However,A feature article in the November 2001 issue of our in-house gazette “Nittoku” included a survey with thequestion, “What is the eco-friendly product which you consider? ”. The products listed below are those thatobtained the highest positions in our “environmentally friendly list” as a result of the survey. The result showsthat sensor-related products received a particularly high evaluation.
Some of the products recognized as environmentally friendly in this survey will be introduced directly by theirrespective developers.

there are maintenance-free spark plugs (no replacement required)available based on the current average life of a vehicle. These
spark plugs are called iridium plugs. They use iridium alloy at thehead of their center electrode and a platinum alloy at the outerelectrodes, and the reduced electrode wear means much better
durability. With a thinner center electrode, they also provide

Main products on the Nittoku Environmentally Friendly List
Automobile-related products

Communication-related products

superior ignition, starting and acceleration.
【How to identify iridium plugs】

Iridium IX plug

Crystal Device and SAW Filter Package

You can easily identify whether or not iridium is used in our spark

Adopts an iridium alloy with a high melting
point at the center electrode. Realizes
excellent combustion efficiency and low fuelconsumption rates.

Small-sized thin packages. Built into thesurface of communication equipment, we aremaking them increasingly smaller and lighter.

plugs by looking at their item numbers. Item numbers starting with

Glow Plug

Organic Build-up Substrates

outer electrodes. Item numbers with “I” or “IX” at the end of the

Meet the requirements of strict exhaustgas regulations in diesel engines. Reduce
the unburned portion of gas.

Based on our unique technology, thesepackages support small-sizing and higherintegration of communication-related
products.

number or before the hyphen that represents gaps, such as KR7AI

Plug Cap and Power Cable

Antenna Switch Module

Control radio wave noise produced in theignition system of the engine. Reduce
loss of spark energy

Low loss and high damping. Supports theminiaturization, weight reduction,shortening and high-density equipping ofmobile terminals.

This is a leading-edge oxygen sensor
that can detect all ratios from rich tolean.

Ceramics-related products
These products conserve energy bymeasuring things like temperature,humidity and wind flow, and using theseblessings of nature for air-conditioning.

Ozonizer/Ionizer
Knock Sensor
Detecting knocking vibration of the engine
with piezo-electric ceramics, these sensors
contribute to lower fuel consumption.

With the strong oxidizing power of ozone,
ozonizers are used to purify and deodorize
water and the air without using chemicals.
Ionizers resolve mold, germs and odors withpower of ion.

Bioceramics
Air Quality Sensor
This sensor is used in car air-conditioner
switching systems, to automatically switch
between internal circulation and outside air
induction modes.

Misfire Detection Unit
Detecting misfire by measuring thedamping time of the plug voltage after
sparking, this device contributes toreduced fuel consumption.

Quick Glow System

Head partand BKR6EIX-11, are not maintenance-free type because they do
not use platinum alloy in the outer electrodes.
Iridium plug

Sensor Division ● Air Quality Sensor

Sensor And Detector For Environment
Multi-range Air Fuel Ratio Sensor

Products development with consideration for the environmentuse iridium alloy for the center electrode and platinum alloy for the

Oxygen Sensor
High reliability sensors that maintain
durability even under severe conditions inengines such as high temperature.

“I”, such as ITR4A15, ITR6F13 and IFR5J11, are long-life plugs and

The various kinds of artificial bones wehave developed using apatite hydroxideand zirconia materials are compatible withthe human body.

An air quality sensor is, as its name suggests, a sensor

Toshiya Matsuoka

that monitors the quality of the air.
This sensor is installed in the air-conditioning system of acar in order to monitor the air outside.
Air-conditioning systems that include this sensor have amechanism by which an “ outside air induction mode ”
works to allow outside air into the car if the air is relatively
clean, or an “inner circulation mode” works to prevent
polluted air from entering the car.
By reacting to CO or NOx emissions from gasoline anddiesel cars, the sensors help prevent not only harmful
gases but also odors from entering.
Air quality sensors fulfill the role of guarding the air inside

Cutting Tools

cars.

Through the utilization of the dry-cutting
method which removes the need for oil,
our cutting tools prevent environment
pollution caused by scattered oil.

We have many other environment-detecting sensors
available, contributing as watchers to global environment.

Air quality sensor

Improving the starting capability of diesel
engines at low temperatures, this system
ensures almost the same starting
capability as that of gasoline cars.

14

15

Product development which considerd environment

Fine Ceramics Division ● Bio ceramics

Semiconductor Components Division ● Crystal Device and SAW Filter Package
The mobile phones used by most people carry small
components called crystal vibrators or SAW filters.
Many of our ceramic packages are used. The parts
play important roles such as identifying the precise
source of radio waves or picking up the object signal
from the tremendous number of signals around. As
mobile phones become smaller, lighter and multifunctioned, these parts are also rapidly becoming
small-sized. For example, the cubic volume of
packages for SAW filters used for RF have diminished
to one fifth (1/5) in the last five years.

The prefix “bio-” brings to mind microbes naturally breaking downorganic compounds, but the bioceramics produced at our Fine
Ceramics Division are very different from this general image, as
they are used for the human body. They include zirconia, amaterial that replaces metal in artificial bone heads in hip joints.
Zirconia reduces abrasion and improves durability, lasting over 10
years without replacement. This product is not only kind to theenvironment but also to human beings. Bioceramic products areused inside the human body, and so they must be highly
compatible with the body so that patients are not aware of theforeign object inside them.

Kentaro Fujikawa

Shinji Maehara

Products development with consideration for the environment

Packages for crystal devices and SAW filters

Bioceramics

Cutting Tool Division ● Cutting Tools

Electronic Components Division ● Antenna Switch Module

There is a reason why mobile phones are becoming increasingly
lighter. It is because the components inside are getting smaller eventhough their performance is actually improving. An antenna switch
module is one such component used in dual-band mobile phones. It isa plate-shaped component less than 1 cm long with the capability to
1 separate frequencies received from the antenna, 2 switch between
the Send and Receive modules, and 3 cut noise from the power
amplifier. While such components are getting smaller and therefore
saving resources, their performance remains impeccable.

Toshitaka Hayakawa■Sectional view of an antenna switch module
Shield metal cap

ResistanceCondenser

Silver wiring

16

Diode

LTCC multilayer substrate

Zirconia head

The main roles of the cutting oil in the cutting process are lubricationand cooling. In low-speed processing with typical conventional materials
such as carbide alloy, we use 100% pure oil to grease the cutting
surfaces. In high-speed processing, on the other hand, we use anemulsified cutting oil, as shown in the photograph, which is a mixture ofrust-preventive oil and water, because we need to cool the cutting tools
when we cut surfaces.
In the current climate of rising awareness on environmental issues,
cutting tools made of alumina ceramics and silicon nitride ceramics andcermet cutting tools are coming into the spotlight. Ceramic-made cutting
tools can process cast iron and cermet cutting tools can process steel,both by dry cutting, a method of cutting without using oil. Dry cutting ispossible with these cutting tools because they can still maintain theirlife-span without cutting oil, and the cut surfaces do not become rough.
This cutting method is easy on the environment for several reasons:first, we do not have the expense of oil. Next, the total cost and energy
consumption is significantly less because we do not need pumps forcirculating oil, coolers for cooling oil, or devices for filtering grinded
powder that may enter the oil during the cutting process. Test
calculations estimate that not using cutting oil can reduce costs by 15%
and energy consumption by 25%. Removing cutting oil that is destined
to be disposed of eventually is a significant contribution to preservationof the environment.

Hiroshi Usui

Antenna switch module

17

Education and awareness activities

Consideration for environment of local communities

We aim to fully utilize every employee's motivationin order to continue our environmental preservation
activities.

Do you practice the eco-friendly thing in thefamiliar place?

Separation of garbage deserves the expression, “Environment preservation starts with the separation of
garbage, and ends in the separation of garbage”. Although separating garbage seems such a small thing,
we have to do it properly before we can do anything important for the environment. We practice reseparation of improperly separated garbage at our Recycle Center by gathering people from thosedepartments responsible for the garbage. We believe this is a useful measure for employee education.

Our factories practice voluntary cleaning activities for the sake of the local
communities who always kindly support us. We also participate in events andactivities conducted by local government agencies and other organizations,where we collect local information on environmental issues and so on, andpromote communication to maintain our principles of harmonious coexistence.

Promotion of environmental education
We regard the following three activities as the keystones of our education.
● We always seek to collect new external information such as environment-related regulations andintroduction of management techniques, and implement education accordingly.
● In order to continuously manage our EMS, we conduct education to maintain and improve the skillsof our in-house auditors, as we place a special emphasis on in-house audits.
● We educate every single employee in each department
every month using standardization instructions, our inhouse magazine and Environment News as texts.

Local cleaning activities
The first thing that we see during the cleaning activities is discarded
cigarette butts. Of course some of them may be thrown away by our
employees, since these butts are found in the neighborhoods of ourfactories. Regardless of who is throwing it away, it should make adults feelashamed before their children.

■Head Office/Factory
June 2001
Participated in “Clean Campaign
Nagoya 2001”

July 2001
Conducted cleaning activities
around the factory

September 2001
Conducted cleaning activities
around the factory

October 2001
Conducted cleaning activities
around the factory

March 2002
Conducted cleaning activities
around the factory

March 2003
New employees conductedcleaning activities■Komaki Factory
Re-separation of garbage

October 2001

■Ise Factory
April 2001
Participated in cleaning activities
on Mt. Komaki

August 2001
Conducted cleaning activities
in neighboring towns

Enlightenment activities

September 2001
Conducted cleaning activities
around the factory

Every month
Conducted cleaning activities
around the main gate

We held the first Environment Congress on June 14, 2001. At thecongress each factory presented examples of their activities such aswaste reduction, energy-saving activities, and so on. Superior
examples for improving the environment received commendations fromthe President. We also held an exhibition where we displayed
diagrams showing examples of improvement, prize-winningenvironmental slogans collected from employees, materials purchased
under the Green Procurement policy, and so on. This event provided an
opportunity for meaningful study and communication.

October 2001
Participated in cleaning activities
in Komaki City

The blue-ribbon environment slogan

Keep our rivers, air, and future clean
The blue-ribbon environment slogan author
Fine Ceramics Division
Katsuhiko Horii

September 2001

August 2001

Participating in the Environmental Partnership
Organizing Club (EPOC)
We participated as an inaugural member of the club when it was formed in February 2000. At present
the club has 310 member companies. Businesses from different industries come together to share
information on environmental and other issues, and to deepen their knowledge through various Expert
Conferences and factory visits. To keep up with the IT age, the club has opened up its information to
the public through its website.

●http://www.epoc.gr.jp
Our Komaki Factory hosted anenvironment workshop and visit
on March 15, 2002, inviting 32
representatives from the members of
EPOC. One of the questions asked
after visiting was why we separated

waste into more than 100
categories. We replied that it wasin order to reclaim the waste as A drainage treatment facility
resources.

18

An improvement case report

The exhibition at the Environment Congress

Recycle Center

19

Consideration for the environment of the local community

March 2002

■Kagoshima-Miyanojo Factory

Environmental accounting

Green Procurement

We will endeavor to systematically and continuously
calculate the cost and effect of environment preservation.

We will try to minimize the impact our purchasedmaterials have on the environment, and actively request
our partners and suppliers to take cooperative action.

We have been practicing environmental accounting in accordance with the guidelines of the Ministry of theEnvironment since 1999. As usual, this report covers four factories consisting of the Head Office/Factory
and the Komaki, Miyanojo and Ise Factories, but does not include affiliated companies.
The reporting period is from April 2001 to March 2002.

We promote environmental conservation through our “Green Procurement”, which is defined below.
We must ensure the following when purchasing goods, services or raw materials:■Environment preservation costs

Unit: Million Yen

Classification

Main efforts

Investment

Expense

474

1,063

Pollution prevention cost

Preventing air pollution, water pollution and noise

Global environment preservation cost

Preventing global warming / Saving energy

8132

Resource circulation cost

Efficient use of resources / Treatment and disposal ofindustrial waste

30

537

512

1,732

0

5

7

392

815

5,745

0

109

0

17

1,334

8,000

Costs within the business area

Social activity cost

Recycling products, etc. / Increased costs accruing
from Green Procurement
Training employees on environmental issues / Building
up and managing EMS
Research and development of products contributing toenvironment preservation
Protecting nature / Expanding green areas /Environment related advertising

Environmental damage correction costCompensation for soil pollution, damage to nature, etc.

Upstream & downstream cost
Management activity cost
R&D cost

Total■Effects of environment preservation
Specific effects
Preventing global warming
Effects on
resources used for Use of waterbusiness activities Quantity of paper used (A4 sheets)
Costs within
the business Effects onarea
environmental
burden and waste
discharged frombusiness activities
Total① Only purchase if absolutely necessary② Where possible, purchase things that are less harmful to the environment③ Where possible, purchase things from partners (suppliers) who are positive about environment
preservation

Requests to partners/suppliers
グリーン調達ガイドライン

In 2001 we performed an “Environment Conditions Survey” covering
about 270 major partners and suppliers to find out their corporate
attitudes toward environmental issues and to ask them for cooperation.
In October 2001, we established and distributed our “Green
Procurement Guidelines” that set out all our requests to our partners
and suppliers, and then held a conference inviting about 170
companies. We plan to expand the number of companies covered so
as to further lighten the burden on the environment together with ourpartners/suppliers.

Encouraging use of “eco” stationery
When we buy office stationery and otherdaily necessaries used in the company, we
select “eco goods” that are less harmful tothe environment. Our “eco” goods
purchase rate in 2001 was 78%, up 10%
from the previous year. We will further
increase this purchase ratio and the qualityof “eco” goods, including switching togoods whose consumable parts are
replaceable or refillable.

Unit: Million Yen

Environmental preservation effectResults in 2001

Comparison with 2000

118,197t-CO2＋4,594t-CO2

1,725,438t※2

60,077kg

Emissions into the air (PRTR substances)

22,790kg

Discharge to water (PRTR substances)

78kg

※3

▲ 67

▲ 171,861t−▲ 20,485kg▲ 25▲ 40,482kg−▲ 58kg−Discharge of waste, etc.

14,764t

Break Quantity reclaimed as resources

13,406t＋4,229t

down Quantity buried/combusted

1,357t▲ 1,044t（▲ 43％）

※4

Economic effect
※1

▲ 125

packing materials

Conventional type

20

100
80
85

60
68

40
20
0

78

80

40
1999

2000

2001

2002

2003 (Fiscal year)(Target)(Target)With the full enforcement of the “Containers and Packages Recycling Law” inApril 2001, not only companies but also society as a whole became moreaware of containers and packaging of products. Since many of our products
are delivered directly to manufacturers as parts for their products, not including
spark plugs which are sold to distributors as replaceable parts, we usually use
trays and commuter boxes instead of individual packaging. In order to improvethese containers and packaging materials from an environmental point of view,
we issued guideline which produced the following results:
Environmentally friendly type■Example of environmentally friendly※1：This economic effect was created by introducing a cogeneration system into the Miyanojo Factory.
※2：We promoted the recycling of water, mainly in the plating process. Recycled water accounted for 36% of the total water used in 2001 (up from
28% in the previous year).
※3：The sharp decrease in discharged quantity was achieved as a result of changing from chlorinated organic solvents and hexachromium to othersubstances.
※4：The increase in waste was caused by enhanced production. However, we reduced the buried/combusted quantity by 43% from the previous year.

We calculate environmental costs by allocating an actual amount of direct capital investment andexpenses according to certain criteria in our accounting rules. As for the economic effect, we donot take deemed effect into account. We need to examine our evaluation of the relation between
our environmental activities, their effect on the environment, and the economical effects fromvarious aspects. We will continue to examine and review these factors in accordance with thelatest guidelines from the Ministry of the Environment.

■An example of an environmentally friendly container（％）

Consideration for the environment with packing
materials for our products＋3,187t▲ 217

２００１年１０月
日本特殊陶業株式会社

Area of effort

Forms of containers and packaging
Conventional typeEnvironmentally friendly type

Semiconductor
packagingSwitched to PET or PSPlastic trays for shipment
materials that are also
made of vinyl chloride
alternative materials

Spark plugs

Blistered bags made of
paper and vinyl chloride

Action plans
1st step: We have already switched materials for new packaging.
2nd step: We are requesting our major customers to change thematerials of their vinyl-chloride trays.
3rd step: We plan to extend our request to our other customers
gradually.

Switched to blistered bags
made of paper and PET

Blistered bags using PET will replace vinyl chloride
for a while.

Switched to suspendedtype paper bags

Adopted in products for Europe
Adoption in products for domestic market underconsideration

21

Environment measurement data by factory
Environment measurement data by factory

Environmental preservation achievements(April 2001 〜 March 2002)
Head Office/Factory

Kagoshima-Miyanojo FactoryClassif
icationParticles of sootAir

Regulation Self-regulation
value
value by law

Item(mg/Nm3)

NOX

(ppm)

SOX

(Nm3/year)

pH

Address: 14-18 Takatsuji-cho, Mizuho-ku,
Nagoya, Aichi Pref.
Founded: October, 1936
Scope of business: Manufacture and sales ofspark plugs and products for engines
Number of employees
1056

150
180

Max

120
−

0.2

45
−

Classif
icationAverage

8

144

−

Min

29
−

3.1
36.3
−

5.0〜9.0

5.7〜8.7

7.1

5.1

6.7

SS

(mg/R)

600

480

130

10

55.8

BOD

(mg/R)

600

480

120

4.8

38.0

n-hexane(mg/R)

30

24

（※）29

＜0.5

8.0

Cyan

(mg/R)

1

0.8

＜0.1

＜0.1

＜0.1

Total chromium (mg/R)
Water Hexachromium (mg/R)

2

1.6

0.17

＜0.04

0.06

0.5

0.4

0.09

＜0.04

＜0.04

Bronze(mg/R)

3

−

−

Zinc

(mg/R)

5

4

0.94

0.05

0.3

−

−

Comment

Lead(mg/R)

0.1

0.08

0.04

＜0.02

＜0.02

As our factory is locatedin an urban area, we takespecial care to control
the effect (particularly
noise) on the surroundingarea and keep it within
our self-regulation values.

Nitrogen(mg/R)

240

192

17

1.8

12

Phosphorus(mg/R)

Colon Bacillus(pcs/cm3)

Factory Chief:
Atsuhiro Chinari

Noise Daytime

32
−

dB

25.6
−

70

3.2
−

68

0.28
−

66.1

Air

Address: 2238-1, Tahara, Miyanojo-cho,Satsuma-gun, Kagoshima Pref.
Founded: April, 1974
Scope of business: Manufacture and salesof spark plugs
Number of employees 555
Comment
To be the world' s
No. 1 plug factory, we
are also taking firm
action to achieveenergy conservationand zero emission.

1.4
59.0

※The cause of n-hexane exceeding the self-regulation value was a flier washed in the kitchen of our canteen.
After making certain of wiping off oil before washing, the recorded value stayed within our self-regulation
value.
All the other items remained within our self-regulation values.

Factory Chief:
Yasuo KimuraClassif
icationAir

Regulation Self-regulation
value
value by law

Item

Factory Chief:
Hiroshi Tanaka

22

Max

Min

Average

300

240

10

10

NOX

(ppm)

180

144

74

74

SOX

(Nm3/year)

−

−

−

−

10
74
−

6.0〜8.0

6.5〜7.8

7.8

7.3

7.5

SS

(mg/R)

35

28

11

4

6.5

BOD

(mg/R)

20

16（※2）174

9.6

n-hexane(mg/R)

5

4

＜2.5

＜2.5

＜2.5

Cyan

(mg/R)

Total chromium(mg/R)

1

0.8

−

−

＜0.05
−

＜0.05
−

＜0.05
−

Water Hexachromium (mg/R)
Bronze(mg/R)

0.5

0.4

＜0.05

＜0.05

＜0.05

3

2.4

＜0.05

＜0.05

＜0.05

Zinc

(mg/R)

3

2.4

0.07

0.05

0.06

Lead

(mg/R)

0.1

0.08

＜0.01

＜0.01

＜0.01
−

Nitrogen(mg/R)−−−−

Phosphorus(mg/R)−−−−

Colon Bacillus(pcs/cm3)

Noise Daytime

−

3000

2400

1800

0

223

65

60

51

47

48.7

dB

※1：We give precedence to values defined by town government protocol rather than by the law. Values
defined by the law are applied if an item is not covered by the above protocol.
※2：The cause of the BOD value exceeding the self-regulation value was water draining from single-type
septic tanks. These were replaced with combined septic tanks by January 2002, bringing the BOD
value within our self-regulation value.
All the other items remained within our self-regulation values.

Classif
icationAverage

Particles of soot(mg/Nm3)

200

160

41

＜2

6

NOX

(ppm)

200

160

110

＜2

61

SOX

(Nm3/year)

pH

Comment
As the company's largest
production plant, this site
has a significant impact on
the environment. We
already meet our selfregulation values, but are
not satisfied with just thatand are making an effort tofurther reduce the burden
on the environment.

Min(mg/Nm3)

Ise Factory

Komaki Factory

Address: 2808, Iwasaki, Komaki, Aichi Pref.
Founded: April, 1962
Scope of business: Manufacture of spark
plugs and products for engines
Manufacture and sales of new ceramics andother applied products
Number of employees 2905

Max

Particles of soot

pH

−

51.9

Regulation value Self-regulation
by law（※1）
value

Item

−

Air

−

Item

Max

Min

Average(mg/Nm3)

250

10

−

−

−

NOX

(ppm)

180

90

−

−

−

SOX

(Nm3/year)

−

−

−

−

6.0〜8.0

6.2〜7.8

7.8

6.8

7.2

pH

−

Regulation value Self-regulation
by law（※）
value

Particles of soot−−

5.8〜8.6

6.0〜8.4

7.7

6.4

7.2
2.3

−

SS

(mg/R)

30

24

11

＜1

4.6

SS

(mg/R)

90

45

5.5

＜1

BOD

(mg/R)

25

20

17

0.7

6

BOD

(mg/R)

25

20

13.8

1.8

5.2

n-hexane(mg/R)

5

4

＜1

＜1

＜1

n-hexane(mg/R)

10

5

＜0.5

＜0.5

＜0.5

Cyan

(mg/R)

0.5

0.4

＜0.1

＜0.1

＜0.1

Total chromium(mg/R)

1

0.8

＜0.04

＜0.04

＜0.04

Water Hexachromium (mg/R)

0.2

0.16

＜0.04

＜0.04

＜0.04

Bronze(mg/R)

1

0.8

0.09

0.01

0.06

Zinc

(mg/R)

3

2.4

1.7

0.01

0.63

Lead

(mg/R)

0.1

0.08

＜0.02

＜0.02

＜0.02

Nitrogen(mg/R)

120

30

17

2.7

8.5

Phosphorus(mg/R)

16

4

0.59

0.2

0.36

Colon Bacillus(pcs/cm3)

Noise Daytime

dB

−

−
70

−
68

−

−
59

Address: 871-6, Hosokoshi, Enza-cho, Iseshi, Mie Pref.
Founded: April, 1994
Scope of business: Design and manufactureof electronic components
Manufacture of semiconductor components
Number of employees 445

51

54.9

※We give precedence to values defined by city government protocol rather than by the law. Values defined by the law
are applied if an item is not covered by the above protocol.
All the items remained within our self-regulation values.
(Complaints against noise)
We were requested by neighboring residents to reduce the noise we were making. Although we were already in compliance withlegal regulation values and our self-regulation values, we satisfied the request by installing acoustic walls, covers andsoundproofing devices (silencers). Since taking these steps, we have been operating without any problems.

Factory Chief:
Masanori Nakashima

Comment
We have achieved ourlong-term plan to fully
abolish chlorinatedorganic solvents. Thisis a great contribution
not only to the global
environment but also
to our operating
environment.

Cyan(mg/R)

−

−

−

−

−

Total chromium(mg/R)

−

−

−

−

−

Water Hexachromium (mg/R)
Bronze(mg/R)

−

−

−

−

−

−

−

−

−

−

Zinc

(mg/R)

−

−

−

−

−

Lead

(mg/R)−−−−

Nitrogen(mg/R)

120

60

22.8

5.3

12.2

Phosphorus(mg/R)

16

8

2.9

0.6

1.6

Colon Bacillus(pcs/cm3)

3000

1000

0

0

0

60

58

54.6

48.7

50.8

Noise DaytimedB−※We give precedence to values defined by city government protocol rather than by the law. Values definedby the law are applied if an item is not covered by the above protocol.
All the items remained within our self-regulation values.

23

Work safety and hygiene

The happiest thing is to be able to work hard ingood physical and mental health.
Our safety management system's principle is “respect for human life”, and its objectives are “toprevent disaster” and “to ensure safe working conditions”. Safety does not mean no disasters, itmeans no danger. We believe that constant preventive measures are as important in safety
management as they are in environment preservation.

Safety and hygiene“Leave home cheerfully and go home safely”. In our company, all the employees appreciate theimportance of such a natural thing. We take all kinds of safety and hygiene action at all offices andfactories in accordance with our “Safety and Hygiene Fundamental Policy” with the aim of eliminating
disasters and danger.
Moreover, in order to ensure safe and comfortable workplaces, we implement regular in-house patrols
and all employees participate in office meetings held twice a year in each section to actively discussand improve our working environment.

Fundamental Safety and Hygiene Policy●The objectives of safety and hygiene management activities are to manage risk and to takepreventive measures against industrial accidents.
●In order to eradicate industrial accidents and prevent disease, all the managers andsupervisors including the President shall keep the safety and hygiene management activities
running smoothly, and all the employees shall work together to build comfortable and safe
workplaces by promoting effective activities in accordance with the principles of safety andhygiene.
●At the same time, all employees shall consider safety and hygiene as their own issue,comply with basic rules, practice “anticipatory” safety and hygiene activities, and make aneffort to maintain or improve their own health.

■Safety and hygiene management system

Conclusion
Activities associated with environmental issues are closely
related to local communities. Once a problem arises, it cangrow into a serious social problem. Therefore, in promoting ouractivities, we should not address environmental issues withconceptual or psychological theories. Instead, we must fully
understand these problems, raise general awareness, and seethem as being our own problems. In order to improve theenvironment, just like our production processes, reducing waste
is a key factor. That is to say, the 3 R's, or reducing, reusing
and recycling, can help us to improve productivity. I believe it isimportant to move firmly and steadily forward with a middle-tolong term outlook.
The company as a whole has already acquired ISO certification
for quality from the same third-party authorizing agency. The
whole company also obtained environmental ISO certification in
2000. The Environment Committees and Expert Committees
help our factories share information and spread it horizontally to
all divisions, enabling us to implement activities smoothly
companywide. At present our affiliated companies are also
working towards obtaining integrated certification. While making
effective use of our environmental preservation systems, we will
also take action to improve our production processes andproduct development giving consideration to the environment,in accordance with our action schedule.
ECO REPORT 2002 reports the results achieved through these
efforts. We intend to continue to promote environment
conservation by reviewing and examining our activities with afresh eye. I hope you will read our future reports to find out
more about our environmental preservation activities.

1
0
2
期

Central Safety and Hygiene Committee
Safety and Hygiene Committee byfactory

作
業
前
に
危
険
予
知

Safety and Hygiene
Subcommittee at eachdepartment/section

慣
油れ
断た
が作
潜業
むに

不
危慣
険れ
がな
潜作
み業
に

安
全
衛
生
ス
ロ
ー
ガ
ン

102期 重点目標①挟まれ災害の撲滅

Office meeting on safety and hygiene②健康管理の充実③作業環境の向上

中央安全衛生委員会

Safety and hygiene patrol

Executive Vice President
Chief Environment Administrator

Handling chemical substances kind to human beings via an MSDS
Proper control and reduction of substances
harmful to the environment is an important
theme for human health as well as forenvironment preservation. In order tosecurely handle these and all other kinds ofchemical substances, we are building up a
database for an MSDS. We have alreadyregistered about 3,000 substances, and aremaking use of this data on our intranet tocontrol the processes of their handling,storage and disposal.

24

Seiji Haga

Chemical Substance Management Systemchemical substance datachemical substance MSDS

6700 items
700 items

MSDS visual information of products we use
Information on laws and regulations
Information on subjects and methods of control
Run
Environment & Safety
Management Dept.

AccessThank you for reading through our “ECO REPORT 2002”. In order to help us improve
future reports, we ask you to please fill in and return the questionnaire enclosed. Please
see the back cover for contact information including the url of our website.

Please kindly send your completed questionnaire sheet to:

All workplaces

FAX

81−52−872−5942

14-18, Takatsuji-cho, Mizuho-ku, Nagoya, Aichi Pref. 467-8525●Issued: September 2002
●Next issue scheduled: August 2003
●Publishing Directors: Seiji Haga
(Executive Vice President, Chief Environment Administrator),
Genjiro Hashimoto(Director, Deputy Environment Administrator)●Editor in Chief: Shunichi Takagi(General Manager, Environment and Safety Management Dept.)●Contacts: General Administration Dept. Public Relations Sec.
Phone 81-52-872-5896

Fax 81-52-872-5999

Environment & Safety management Dept.
Phone 81-52-872-5980
Fax 81-52-872-5942』and back issues of『also available from our website:『are』