JICA Project for Capacity Development Asisstance for Low Carbon Development in the Republic of Indonesia Jakarta, 7 December 2017 IMPLEMENTATION OF EMISSION REDUCTION USING CO-GENERATION IN CAR MANUFACTURING by F Sales Sudaryono Plant Engineering & SHE Division Head PT. Toyota Motor Manufacturing Indonesia [TMMIN] 1
Outline 1. CO 2 Emission in Indonesia & Policy 2. Toyota Action of CO 2 Emission Reduction 2.1. Toyota Global Action & CO 2 Emission Reduction Challenge 2.2. Toyota Asia Pacific CO 2 Reduction milestone 2.3. Toyota Indonesia [TMMIN] Profile, Action & Roadmap 3. TMMIN Co-Generation Project Overview 4. Future Action 2
Overview of TOYOTA Indonesia TOYOTA has two local companies in Indonesia, which are TMMIN for vehicle manufacturing and TAM for distribution Toyota Motor Manufacturing Toyota-Astra Motor Indonesia (TMMIN) (TAM) Vehicle/ Parts Production and Export Business Area Vehicle/Parts Distribution 50% 95% 5% 50% Investment Ratio Domestic Market Share Export Destination [CBU, Component, Service Part, Tool] more than 80 Countries [as Jan-Sept 2017] 3
Toyota Motor Mfg Indonesia [TMMIN] Business Overview UNIT & COMPONENT PLANT VEHICLE PLANT Karawang 1 Karawang 2 KRW#3 Sunter 1 Sunter 2 Location Karawang- West Java North Jakarta Start of 1998 2013 2016 1973 1977 Production Etios Valco Stamping Production Line- Kijang Innova; Vios, Limo RNR Engine TR Engine parts/dies; Up Fortuner Yaris & Sienta castings Engines: 195,000 unit/Y Annual 130,000 unit/Y 120,000 unit/Y 216,000 unit/Y Iron castings: 12,000 to n/Y Production Land area : 100 Ha 150 Ha Capacity 4 Ha 15 Ha ± 3.500 ± 1.500 ± 1.200 ± 1.300 ± 2.000 No of Employee Engine TR Engine NR 4
1. CO 2 Emission in Indonesia & Policy Indonesian Goverment take action by setting policy as commitment in Paris Agreement COP-22 1. Energy Efficiency 2. Energy Conservation *Source : National Energy Policy – KEN PP no. 79/2014 5
Toyota Action to Reduce CO 2 Emission 6
2. Toyota Commitment of CO 2 Emission Reduction Toyota has inherited a corporate philosophy “Challenge” to cope with environmental issues as one of the top priority overlooking for the next 2 to 3 decades Concrete Action of Toyota Six Challenges Long- term Vision “ Toyota Environment Challenge 2050” Challenge to ZERO & Beyond 7 *Source : TMC Chairman, Mr. Uchiyamada on Toyota Environment Forum 7
2. Toyota Commitment of CO 2 Emission Reduction 2.1. Toyota Global Action & CO 2 Emission Reduction Challenge Challenge3 - Plant Zero CO 2 Emission 8 *Source : TMC Chairman, Mr. Uchiyamada on Toyota Environment Forum 8
2. Toyota Commitment of CO 2 Emission Reduction Aim to reduce CO 2 emission from all over Toyota’s Plant world wide Initiatives for reduction by low CO 2 production technologies and daily Kaizen activities 9
2. Toyota Commitment of CO 2 Emission Reduction 2.2. Toyota Asia Pacific – CO 2 Reduction Strategy Toward 2030, Toyota in Asia Pacific set scenario which aim to reduce CO 2 emission 10
Implementation of CO 2 emission Reduction in Toyota Asia Pacific Low CO 2 Emission technology applied in all Toyota Asia Pacific & will be expand more in the future Co-Gen 5.7MW Solar PV 50 KW Solar PV Solar PV 0,5 MW 10 KW Solar Roof Top 1 MW Solar PV 3.2 MW [JCM Scheme] Solar PV 200KW Solar PV 500KW 11 Co-Gen 7,8 MW Solar Roof Top 40 KW [ JCM Scheme]
Implementation of CO 2 Emission Reduction in Toyota Motor Manufacturing Indonesia 12
TMMIN Milestone of CO 2 Emission & Water Reduction Steady improve daily activities & adoption of the latest innovative low CO 2 & water reduction technologies CO 2 AWARD & RECOGNITION Purchased : 100% AWARENESS Face to Face Communication Continuos Education Improvement Green Award by Env. Award by ASEAN Best Energy KRW Regent Ministry of Env. Award in Laos 2015 Participating COP 23 2016 2016 Bonn – Germany, Nov ’17 Karakuri Automation System Water Spray CO 2 Target 3 Wet Rain Water Painting ENERGY Recycle Facility Process EFFICIENCY Purchased : 80% Economizer & Achievement Membrane Bio Inverter FY15-current : Reactor (MBR) approx. 11% Substitute to RO Natural Gas ENERGY Purchased : 5% CONSERVATION Solar PV Co-Generation 2017 2025 2050
Daily kaizen [Example]- initiatives for Karakur i mechanism What is “ Karakuri Kaizen ” ? KARAKURI means : Use mechanical equipment device to create movement without external energy Toyota Indonesia participate in Japan Karakuri Exhibition 2017 ORIGINAL APPLICATION Gravity Spring (weight) KARAKURI NINGYO PHYTAGORA SWITCH Japanese Mechanized Puppet Trick Mechanism UTILIZED ITEMS Magnetic Gear Force Balance Link Differential Cam Action Utilize mechanical energy Adopt for Production Wisdom & Ingenuity Equipment [No electric power] Application Example in TMMIN Eliminate Electric from Conveyor Energy Less [Use roller & gravity] [Use gravity to transfer part] 14
OVERVIEW JCM – Indonesia [Joint Credit Mechanism] TMMIN Co-Generation Project 15
JCM Indonesia & Mechanism Joint Crediting Mechanism is a proposal by Government of Japan to encourage Japanese private sector organizations to invest on Low Carbon Development activities in Indonesia by giving incentive. The Government of Indonesia and The Government of Japan have been signed a cooperation agreement on August 2013 JCM Toyota Motor Manufacturing Indonesia Toyota Tsusho Corp Jpn [TMMIN] 16
TMMIN Co-Generation System Image Gas Engine CO2 Emission Reduced Ton CO 2 / Year 20.311 Ton CO 2 / Year 38.493 18.182 17 Co-Generation Plant Overview
4. Future Action Innovative Technology & Daily Kaizen & Low CO 2 Technology Renewable Energy Proactively use renewable energy with consideration for local characteristics and economic efficiency Renewable Energy Innovative Low CO 2 technology 2001 2030 2017 2050 Study renewable energy [regulation, technology , economical investment scheme.etc] 18
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