Green Factories
Honda has aggressively reduced the use of energy and other resources and made progress toward zero emissions in production, in accordance with its Green Factory initiative.
* Covers five factories in Japan: Saitama, Tochigi, Hamamatsu, Suzuka and Kumamoto factories
Energy conservation
•CO2 Emissions and Per-unit Energy Consumption
Note: Per-unit energy consumption values are shown as indices (FY1991=100%).
CO2 Emissions calculated according to the following formulae:
| Electricity | 0.378 CO2 tons/MWh |
| Natural gas (13A 46MJ) | 2.330 CO2 tons/1,000 Nm3 |
| Natural gas (13A 45MJ) | 2.277 CO2 tons/1,000 Nm3 |
| Kerosene | 2.489 CO2 tons/kl |
| Diesel oil | 2.619 CO2 tons/kl |
| Gasoline | 2.322 CO2 tons/kl |
| LPG | 3.000 CO2 tons/ton |
Notes:
Electricity: Formula designated in Japan's Ministry of the Environment guidelines for calculating greenhouse gas emissions (V. 1.6)
Fuels: Factor used in the reporting system established under the Law Concerning the Promotion of Measures to Cope with Global Warming
•Mid-term Targets and Progress
In FY2007 energy consumption per unit was reduced 29.8%, exceeding the target of a 24.0% reduction from FY1991 levels.
Energy savings
•Energy conservation initiatives
•Implementation of cogeneration system (Kumamoto Factory)
•Introduction of natural gas use (with implementation at Tochigi Factory, all factories in Japan have completed this transition)
•Introduction of high-efficiency compressors
•Introduction of hydraulic inverter control units
•Change in Unit Output in Japan
Note: From FY2000 onward, ATVs, which had previously been classified as power products, were reclassified as motorcycles.
CO2 emissions attributable to use of energy in the production domain totaled 463,000 tons, 7.4% lower than the target of 500,000 tons (21.3% lower than FY1991 emissions) and 1.5% lower than last year's total of 470,000 tons. Measures implemented in FY2007 (see below) and weather allowing for reductions in heating and air conditioning were the main factors contributing to the decline. To further reduce energy consumption, Honda will continue to promote energy conservation, introduce new energy sources and efficiently monitor energy use by applying our LCA process.
Introduction of new energy sources
•Power Generation from New Energy Sources
Note: Solar power generation and natural-gas cogeneration are considered new energy sources according to definitions contained in Japan's Law Concerning Special Measures to Promote the Use of New Energy)
Consumption of new energy sources in the production domain totaled 67.1 million kWh in FY2007, accounting for approximately 8% of total electricity consumption. Solar power generation equipment was installed at the Tochigi and Suzuka factories and a cogeneration system was installed at the Kumamoto Factory. Further, the operation of cogeneration systems was made more efficient as a result of an adjustment taking into account the balance between electricity generation and heat consumption. We will continue to work toward further improvements in efficiency and further reduction of CO2 emissions.
Greenhouse gas emissions
•Greenhouse gas emissions
•CO2 emissions from energy consumption and waste incineration: 464,000 CO2 tons
•Emissions of greenhouse gases other than CO2: 5,000 CO2 tons
Note: Greenhouse gas emissions (CO2, CH4, N2O, HFC, PFC, and SF6) calculated according to the guidelines provided by Japan's Ministry of the Environment.
In FY2007 greenhouse gases emitted in the production domain totaled 469,000 CO2 tons. Through more efficient use of gas recovery equipment during the introduction of gas (HFC) into automobile air-conditioning systems, and other measures, HFC emissions were reduced.
Resource (water use) conservation
•Water Consumption and Unit Water Consumption Index
Note: Unit water consumption values are shown as indices (FY2001=100%).
Note: an error in calculating water use in FY2006 has been corrected.
•Water Conservation Measures Implemented in Fiscal 2007
•Recycling of water recovered from wastewater treatment
•Reduction of water supply required due to improvement of efficiency of cogeneration system operation
•Recycling of cooling water used in forging
Water used in the production domain decreased 10.8% from FY2001 levels to 4,700,000m3. The unit water consumption index decreased 24% from FY2000 levels. The decline can be attributed to an increase of 92,000 m3 in rainwater use, and a reduction of discharges into the sewer system.
Waste Elimination
Reduction in waste (byproducts)
•Trends in Internal Waste Incineration and Recycling Rate
•Breakdown of Waste (Byproducts) Associated with Production
(1,000 tons)
| Type |
FY2005 |
FY2006 |
FY2007 |
| Off-site landfill |
0.00 |
0.00 |
0.00 |
| External disposal by contractors |
0.10 |
0.02 |
0.12 |
| Internal incineration |
4.38 |
2.11 |
1.35 |
| Internal concentration |
6.03 |
6.91 |
6.27 |
| Recycling |
176.91 |
189.40 |
206.35 |
| Total waste volume |
187.42 |
198.44 |
214.09 |
Note: Excluding incinerated residues
Note: method used to calculate the breakdown of waste for FY2005 and FY2006 has been revised and recycling rates corrected.
All factories in Japan maintained their record of zero direct off-site landfill waste in FY2007. In addition, recycling volumes were increased and the volume of waste and byproducts incinerated was reduced. The amount of waste incinerated was approximately 1,400 tons in FY2007, a 91% reduction from FY1999 levels. Internal processing of mill ends was moved to external recycling, leading to an increase in the volume of recycled materials and recycling rate. We will further reduce waste incineration by improving waste segregation and recycling and proactively reducing the total volume of waste and byproducts by preventing their generation at source.
•Per-Unit Byproduct Generation of (FY2002=100%)
Note: based on a review of the analysis of recycling processes, historical data has been revised.
In accordance with Japan's Law for the Promotion of Effective Utilization of Resources, Honda is engaged in an initiative to reduce the volume of byproducts it generates (metals and casting aggregates) (shown in the adjacent graph). The byproduct generation target of a 3% reduction from the FY2002 baseline was achieved (a reduction of 2% from FY2006) through improvements to production processes. We will continue striving to improve production processes, and take other measures to reduce the generation of byproducts.
Prevention of air and water pollution
Gas emissions from combustion systems and factory wastewater are closely monitored to maintain air and water quality at levels according to Honda's voluntary standards, which are more stringent than the government regulations. (For specific measurement results, please refer to Japan Factory Data.)
Elimination of Substances of Concern
VOC* emissions
•Measures implemented in FY2007 to reduce VOC emissions
•Comprehensive reductions in waste and loss (better recovery of thinners used in cleaning, and other measures)
•Improved painting efficiency through the introduction of robots and stationary electronic painting devices, and other measures
•Continuing introduction of water-based paints
•Trend in Per-Unit VOC Emissions
* VOCs mainly consist of organic solvents contained in paints and adhesives. VOCs remain toxic for a long period of time, causing depletion of the ozone layer in the stratosphere and photochemical smog in the troposphere. For these reasons, their use is regulated in many countries.
The main source of VOC emissions is solvents used in automobile paint processes. In FY2007 average VOC emissions from these factories were 33.0 g/m2, a 1.3 g/m2 reduction from FY2006, and 1.8 g/m2 lower than the original target. Principal measures implemented to achieve this reduction are detailed below. We will continue working toward FY2011 VOC emissions reduction targets by extending the use of water-based paints, introducing high-efficiency painting lines and implementing other measures.
PRTR* Emissions
•Emissions of Substances Treated under the PRTR System and Per-Unit Emission Indices
Note: PRTR per-unit emission values are as indices (FY2002=100%).
•Breakdown of the Emissions of Substances Treated within the PRTR System
The adjacent charts provide statistical data for FY2007 regarding chemical substances within the scope of the PRTR system. The volume of emissions discharged into the atmosphere/hydrosphere was approximately 1,925 tons, 30% lower than FY2002. The PRTR per-unit emission index declined 33% from FY2002. We will continue to strive for reductions in the use of these substances in conjunction with measures to reduce VOC emissions. (For further details on emissions, please refer to Supplementary Data.)
* The PRTR Pollutant Release and Transfer Register) system is based on Japan's Law Concerning the Reporting of Specified Chemical Substances Released into the Environment and the Promotion of Improvements in their Management.
Report Concerning the Storage and Disposal of Devices Containing PCBs
In FY2007 we submitted a report to the Japanese government on 739 condensers and transformers containing PCBs. We have concluded an agreement with the Japan Environmental Safety Corporation for pre-processing. We are storing these devices in compliance with government storage standards, ensuring that PCBs do not leak into the environment. Moreover, we are taking step to ensure the proper and prompt disposal of these devices.
