2009 Case Studies and Supplementary Information Environmental Annual Report Honda Environmental information disclosure South America Automobiles 158,000 Motorcycles 1,557,000 Power products 111,000 Japan Automobiles 580,000 Motorcycles 233,000 Power products 514,000 China Automobiles 480,000 Motorcycles 1,288,000 Power products: included in figure for Asia/Oceania Asia/Oceania Automobiles 354,000 Motorcycles 11,000,000 Power products 1,252,000 Europe/ Middle East/Africa Automobiles 460,000 Motorcycles 340,000 Power products 1,404,000 North America Automobiles 1,518,000 Motorcycles 317,000 Power products 1,907,000 Annual sales in Honda’s six regions by unit volume (FY2009) Global Operations and Marketplace Advancing operations in six regions Driven by its philosophy of building products close to the customer, Honda manufactures its products in six different regions worldwide. In FY2009 we delivered 23 million units to customers around the world. Always conscious of the environmental impact of its operations, Honda is working hard to take environmental responsibility to ever higher lev- els around the world. In 2006 Honda became the world’s first automaker to announce global CO 2 reduction goals for its products and production activities. It also implemented a proactive strategy to help stabilize climate change, taking efforts to even higher levels. As a global manufacturer, Hon- da strives to develop products with the lowest in-use CO 2 emissions manufactured at plants with the lowest per-unit CO 2 emissions. Honda Group companies worldwide continue to advance a wide range of ini- tiatives for the reduction of environmental impact. Honda discloses its environmental policies and practices in the CSR Report, in the Honda Environmental Annual Report and on its website (http://world.honda.com/environment/). The CSR Report outlines Honda’s environmental initiatives in an easy-to-understand way. The Environmental Annual Report presents in greater detail Honda’s fundamental policies and future direction with respect to the environment, as well as the results of the year’s environmental initiatives. In addition to covering both general and specific environmental information, the website presents the history of Honda’s environmental initiatives. Starting this year, Honda is presenting the report in two parts: “Honda Environmental Annual Report 2009” and “Hon- da Environmental Annual Report 2009: Case Studies and Supplementary Information” are both available on the website, and “Honda Environmental Annual Report 2009” is also available in printed form. As restructured, the printed Report will play an even stronger role in our Plan, Do, Check and Act (PDCA) process for environmental initiatives. The Case Studies and Supplementary Information document supplements the information con- tained in the printed Report, introduces additional initiatives in each domain and presents Substances of Concern output data for each Honda facility and product area. Honda produces the Honda Environmental Annual Report based on internal guidelines. By disclosing a wide range of information, we hope to facilitate communication and feedback, thereby strengthening our environmental conservation initiatives going forward. 2 Honda Environmental Annual Report 2009 Product development 4 Purchasing 7 Transportation 7 Product recycling 9 Administration 12 Additional information Philanthropic initiatives 13 Maximizing the use of microgrid-generated energy 14 Automobile R&D Center, Honda R&D Co., Ltd. Toward a 100% recycled water system 16 Honda Engineering Co., Ltd. Green Factory initiatives 18 Tochigi Factory, Honda Motor Co., Ltd. Solar power generation performance boosted 15% 20 Tsuzuki Manufacturing Co., Ltd. “Team Minus 6%” reduces environmental footprint 22 Honda Cars Aichi Co., Ltd. Honda Soltec solar panels help power dealership 23 Honda Cars Mito Co., Ltd. Automobile environmental performance information (Japan) 24 Motorcycle environmental performance information (Japan) 35 Power Products environmental performance information (Japan) 38 ISO/EMAS certification 39 Japan facilities information 41 Honda Motor Co., Ltd. 41 Honda R&D Co., Ltd. 60 Honda Engineering Co., Ltd. 71 PRTR-listed substances (production domain) 73 Analysis of sewage by facility 74 Philanthropic environmental initiative information 75 C O N T E N T S 4 13 Honda Group companies case studies 14 23 Initiatives in Japan Additional information 24 77 3 Honda Environmental Annual Report 2009 Initiatives in Japan Honda is striving to reduce the noise caused by acceleration. The main sources of acceleration noise are the engine, the intake and exhaust systems, and the tires. The technologies listed below were implemented in the Insight released in February 2009 in Japan to suppress engine and intake and exhaust noise, reducing exterior noise to 72 dBA, lower than the 76 dBA required by regulations. Noise reduction Product development Automobiles All-new and redesigned vehicles introduced in FY2009 attaining 2010 standards Insight, Freed FF, Odyssey FF (some types) Life FF (some types), Odyssey 4WD (some types) Accord FF (some types), Accord Tourer FF, Freed 4WD, Life FF (some types), Life 4WD (some types), Odyssey FF (some types), Odyssey 4WD (some types) Principal noise/vibration reduction technologies • Engine noise reduction technology · High-rigidity cylinder block · High-rigidity crankshaft · High-rigidity chain case · Stiffener, integrated aluminum oil pan · Hood insulation · Engine compartment undercover • Intake noise/radiant noise reduction technology · High-volume, high-rigidity air cleaner · High-volume, high-rigidity resonator chamber • Exhaust noise/radiant noise reduction technology · Noise-absorbing chamber · Long tailpipe silencer · 2-layer heat cover 2010 fuel economy standards + 25%: 3 models 2010 fuel economy standards + 10%: 2 models 2010 fuel economy standards + 5%: 5 models Air cleaner Resonator chamber Silencer Chamber 4 Honda Environmental Annual Report 2009: Case Studies and Supplementary Information Since October 2007, all Honda automobiles sold in Japan have met the guidelines for in-vehicle VOC content man- dated by Japan’s Ministry of Health, Labor and Welfare. Honda is the first automaker to achieve these standards for all automobiles, including commercial vehicles. Reduction of in-vehicle VOCs The completely redesigned, fourth- generation Honda Odyssey was released in October 2008. It is available with a 2.4-liter i-VTEC engine that combines reduced precious metals content with enhanced emissions performance. The latest model features a newly developed integrated cylinder head exhaust manifold and an extremely heat-resistant catalytic converter located directly beneath the manifold. Together, these technologies maintain a highly efficient system for purifying exhaust emissions with reduced use of rare precious metals. The Odyssey features a linear air-fuel ratio sensor, an oxygen sensor and an air-flow sensor for high-precision air-fuel ratio control, while a high-atomizing fuel injector helps reduce exhaust emissions. These technologies give the Odyssey enhanced emissions performance, allowing certain types to be certified as very low-emission vehicles by Japan’s MLIT. Introduced in 1994, the Odyssey reached cumulative sales of one million units in Japan in February 2009. Exhaust emissions Resin intake manifold in Insight Honda sought to maximize fuel efficiency and environ- mental performance in every detail of the 1.3-liter gasoline engine that serves as the Insight’s main source of power. Be- tween the cylinder heads and the intake manifold, Honda placed an EGR plate with highly efficient exhaust pathways. The implementation of this technology allowed for the use of a lightweight composite-resin intake manifold, helping to reduce overall vehicle weight. Designing the 3R’s (reduce, reuse, recycle) Case Studies Even cleaner Odyssey emissions 5 Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information Integrated cylinder head exhaust manifold Linear A/F sensor High-heat-resistanct catalytic converter Under-the-floor catalytic converter O 2 sensor A cogeneration (heat and electricity) system generates electricity with a gas engine and uses the exhaust heat to supply hot water. Overcoming the challenge of creating a system compact enough for household use, in March 2003, Honda be- gan sales of a cogeneration unit that combined the GE160V—the world’s smallest natural gas engine—with an electrical generation system featuring Honda’s original sine wave inverter technology. In Japan, a cogeneration system that incorporates Honda’s compact household cogeneration unit has been sold through utility gas companies under the brand name ECOWILL. In October 2006, Honda introduced a new unit featuring power generation efficiency of 22.5% and total energy ef- ficiency of 85.5%. In FY2009, in Japan Honda sold 20,021 units of the ECOWILL cogeneration system. Cumulatively, Honda has sold 86,285 units since its release. Sales results for compact household cogeneration systems Power Products In December 2008, Honda launched the Yukios SB800, a compact and lightweight snow thrower that clears snow with a blade in an easy-to-use fashion. In addition to exceptional fuel economy, the Yukios SB800 features low noise. When the user releases the throttle lever, engine rpms automatically decrease for enhanced fuel economy and reduced noise during idling. The use of a resin engine cover further reduces noise to facilitate early morning snow removal. In February 2009, Honda introduced the Pianta FV200 gas-powered mini-tiller, which runs on home-use butane gas canisters. As with the Yukios SB800, when the user releases the throttle lever, engine rpms automatically decrease to reduce noise. In addition, noise is reduced through the use of a large silencer, provided as standard equipment, along with a plastic engine cover. Noise reduction Advances in solar cell production and sales In October 2007 Honda Soltec began commercial production of non-silicon CIGS (copper, indium, gallium and selenium) thin-film solar cells developed by Honda Engineering. The width of the energy-generating layers of CIGS solar cells is approximately 2.4 micrometers, roughly 1/80th the width of polycrystal silicon cells. Produced with fewer processes and less energy than polycrystal silicon cells, CIGS solar cells have an approximately 1/3 shorter energy payback time (the time it takes to recover the energy used in cell production) of 0.9 years. One challenge faced in the development of CIGS solar cells concerns the ho- mogeneity of the energy-generating layer. Whereas polycrystal silicon has a maxi- mum cell size of 15 cm, Honda can produce CIGS substrates that measure as much as 73×92 cm. To accomplish this, Honda implemented such original technologies as in-plane temperature distribution with high-temperature processing exceeding 500°C and doping technology based on automotive coating technology. Honda thin-film solar cells have a highly efficient 11.15% energy-conversion rate. Honda Soltec has begun selling the cells throughout Japan. Alternative energy Other initiatives Installation at Kumamoto Factory 6 Honda Environmental Annual Report 2009: Case Studies and Supplementary Information Initiatives in Japan Purchasing Since most molds are made of metal, they are recycled. However, since some molds are used for many different service replacement parts, it can be difficult to determine when they can be recycled. In FY2003 Honda began sharing guidelines with suppliers on mold recycling, leading to standardization of procedures and more proactive recycling. Recycling of used molds • 10,119 molds recycled • 1,410 tons of molds recycled • 9,760 molds recycled • 1,360 tons of molds recycled Results for FY2008 Results for FY2009 Transportation Reducing packaging in the transportation of component parts sets Completed motorcycles importation and power products transportation By using returnable cases when importing scooters from China, Honda is continuing to maintain zero landfill dis- posal of shipping materials. By eliminating the use of cardboard and introducing returnable steel containers, Honda continues to reduce packaging use. In addition, through the use of returnable steel cases for transporting medium and large marine outboards in Japan, Honda is continuing to reduce steel and cardboard use. Using less packaging in the import/export of motorcycles Measure Reduction Reduced use of steel 482 tons Reduced use of cardboard 750 tons Using less packaging in the transportation of power products Measure Reduction Reduced use of steel 71 tons Reduced use of cardboard 0 tons 7 Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information In FY2009 the company used 18,069 tons of packaging materials, a reduction of 3,116 tons, or approximately 15%, from FY2008. As in FY2008, the use of returnable containers in coordination with charter flights contributed to the reduction. Honda uses cardboard boxes in the receiving, shipping and storage of small parts but is increasingly using returnable containers to store them. Gradually seeing results from this initiative, the company plans to expand it going forward. In the area of large parts, Honda has focused on replacement bumpers, for which there is high demand, creating a simple, environmentally respon- sible package. As a result, Honda has eliminated cardboard replace- ment bumper packaging and reduced the total amount of packaging that bumpers require. Parts packaging initiatives 0 5,000 10,000 15,000 20,000 25,000 2005 2006 2007 2008 2009 21,369 22,677 21,891 21,185 18,06918,069 Previous system Cardboard box outside + foam sheet inside New system Foam sheet only Implementation of returnable storage containers Supplier Packaging Shipping Wholesaler Dealer Packing (cardboard) Disposal of cardboard Disposal of cardboard Warehousing Japan shipping Incineration of cardboard Supplier Packaging Shipping Wholesaler Dealer Packing Incineration of cardboard After implementing returnable containers Trend in packaging materials for service parts Simplication of replacement bumper packaging Supplier- specific buckets Reduction of cardboard used Warehousing Returnable container Japan shipping 8 Honda Environmental Annual Report 2009: Case Studies and Supplementary Information (FY) (Tons) Initiatives in Japan Development initiatives Product recycling Reducing the use of SOCs Automobiles Honda is working to reduce the use of four heavy metals considered to have adverse effects on the environment (lead, mercury, hexavalent chromium and cadmium). In the production of the Insight and other vehicles released in FY2009, Honda attained the reduction targets set by the Japan Automobile Manufacturers Association (JAMA; see adjacent chart). The company expanded, by approximately 10%, the installation of air conditioners that reduce the use of HFC134a (baseline: FY1996), using them in 22 out of 24 models. Honda is examining the viability of implementing air conditioners that use no HFC134a, and is monitoring new technological developments. By discontinuing the use of PVCs in interior and exterior resin parts, Honda reduced the content of chlorine in automobile shredder residue to 1% or less in all new models released in FY2009. Motorcycles One of Honda’s commitments is to reduce the use of four heavy metals (lead, mercury, hexavalent chromium and cadmium) in all models produced in Japan by the end of 2005. The company attained its voluntary reduction targets by the end of FY2007 and in FY2009 continued to operate within target levels. Honda also eliminated in Japan the use of polycyclic aromatic hydrocarbons, prohibited under 2010 European regulations. Power Products Honda also committed itself to reducing the use of four heavy metals (lead, mercury, hexavalent chromium and cadmium) in all power products produced in Japan by the end of 2006. No regulatory standards for power products are in effect in Japan, but Honda is working to voluntarily reduce the use of SOCs in power products in accordance with JAMA’s voluntary targets. Honda has already attained the targets for lead, mercury and cadmium. Honda has eliminated the use of hexavalent chromium for all purposes except for anti-corrosion treatments in certain marine outboards. JAMA voluntary reduction targets (new automobiles) Target substance Lead Mercury Hexavalent chromium Cadmium Target period Starting in 2006 Starting in 2005 Starting in 2008 Starting in 2007 Details Amount per vehicle (baseline: 1996) (Automobiles: 10% or less) (Motorcycles: 60 g or less) Banned except for some parts (small amounts allowed in high-discharge headlights and LCD panels for navigation systems) Banned Banned Note: Exceptions provided for in the case of lead and mercury 9 Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information Recycling oil lters Honda collects and disassembles end-of-life oil filters to recycle them as metal and fuel. Honda also reuses some of their components as production parts. The company has started recovering these filters through Honda dealers nationwide in January 2004 and began recover- ing filters from service and repair companies in FY2006. Honda’s goal is to recover 30% of the oil filters produced in the previous fiscal year. Recovery and recycling of bumpers Honda has established a system to collect used bumpers from deal- ers and recycle them as raw material. In FY2009 the company recov- ered 239,00 used bumpers from Honda automobile dealers and service and repair companies, recovering a total of 814 tons of resin. Of this amount, 236,000 bumpers (803 tons of resin) were to be replaced, and 3,000 bumpers (11 tons of resin) were collected from end-of-life ve- hicles. Honda used a total of 1,204 tons of recycled bumper resin in such parts as replacement bumpers, splash shields and splash guards for automobiles and undercovers for motorcycles. Use initiatives Flow of oil filter recycling 厨厨 厨厨厨厨 厨厨厨 Replacement oil filters Filters put in pails Parts cleaned Steel recycled, filters used as fuel End-of-life filters Oil removed Disassembly Incorporated into the manufacture of new filters Recyclable parts wrapped and shipped Dealer Sent to disassembly facility Disassembly facility Sent to oil filter factory Shipped to dealer 2005 2006 2007 2008 2009 0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 51 55 51 49 70 940 969 937 872 803 11 1,204 11 6 11 14 1,454 1,641 1,479 1,378 2005 2006 2007 2008 2009 0 100 200 300 400 276 285 276 256 000 3.0 2.0 3.0 4.0 3.0 236 Bumpers and resin recovered Bumper resin recovered and used Note 1: The amount of resin reused was greater than the amount of resin collected due to stocks held over from the previous year and the recycling of defective bumpers never used as parts. Note 2: Since FY2004, one bumper has been calculated as weighing 3.4 kg. End-of-life lters are disassembled and recycled 10 Honda Environmental Annual Report 2009: Case Studies and Supplementary Information 1,000 bumpers (FY) (FY) Bumpers replaced for repair Bumpers replaced for repair Resin reused End-of-life vehicle bumpers End-of-life vehicle bumpers (Tons) [...]... low-emission vehicles exhibits, see Case Studies and Supplementary Information p75 • Hosting environmental exhibitions For information on cooperating with communities, see Case Studies and Supplementary Information p76 For information on environmental awards Honda has won, please see Case Studies and Supplementary Information p78 [URL] http://www .honda. co.jp /environmental- report/ Corporate advertising •... economy standards +5%; 4 attain 2010 fuel economy standards +10% Of 1,307 vehicles, 2 attain 2010 fuel economy standards; 644 attain 2010 fuel economy standards +5%; 285 attain 2010 7 fuel economy standards +10%; 1 attains 2010 fuel economy standards +15%; 70 attain 2010 fuel economy standards +20%; 117 attain 2010 fuel economy standards +25% 12 Honda Environmental Annual Report 2009: Case Studies and Supplementary. .. catalogues [URL] http://www .honda. co.jp/cmdata/ Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information 13 Honda Group companies case studies Maximizing the use of microgrid-generated energy • Automobile R&D Center, Honda R&D Co., Ltd Aiming to be an R&D center with the world’s smallest environmental footprint the Automobile R&D Center implements advanced environmental initiatives... in Eco Drive classes Honda Environmental Annual Report 2009: Case Studies and Supplementary Information 4,623 Gasoline Introduction of cool biz, warm biz practices 22 49 35 Case study: Honda Group automobile dealerships Honda Soltec solar panels help power dealership  • Honda Cars Mito Co., Ltd In October 2008, Honda Cars Mito merged the Katsuta West and Katsuta North dealerships and reopened Katsuta... and roof 400 m2 green roof (Phyla nodiflora) High-efficiency lighting (including LEDs) Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information 19 Honda Group companies case studies Solar power generation system performance boosted 15% • Tsuzuki Manufacturing Co., Ltd Tsuzuki Manufacturing Co., Ltd is a Honda affiliate engaged in manufacturing of transmission components and. .. Drive power central monitoring system Heat and water sources Machine operation management/energy data management Monitoring system •  VAC monitoring via H intranet •  ower generation by P facility Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information 15 Honda Group companies case studies Toward a 100% recycled water system • Honda Engineering Co., Ltd Due to the experiments... Feb 2009 0 m3/year Manufacturing processes Discharge 0 m3/year Boilers Purification mechanisms 20,000 m3 /year Boiler evaporation volume 5,000 m3/year Industrial wastewater treatment 25,000 m3/year Reverse osmosis 25,000 m3/year Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information 17 Honda Group companies case studies Green factory initiatives • Tochigi Factory, Honda. .. tons and no more than 2.5 tons Manual Other than manual . Environmental Annual Report 2009 and “Hon- da Environmental Annual Report 2009: Case Studies and Supplementary Information are both available on the website, and Honda Environmental Annual Report 2009 . system of Honda R&D Co., Ltd. Microgrid control Monitoring system 15 Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information Honda Group companies case studies In. 2008 2009 426 445 438 381 311 3,200 3,340 3,290 2,860 2,332 Batteries and lead recovered 11 Honda Environmental Annual Report 2009 : Case Studies and Supplementary Information (FY) (Tons) (Thousands) Used