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Moving Up The Recycling Learning Curve
Ryan McMullanCorporate Responsibility
Toyota Motor Sales
Who is Toyota?• Toyota Motor Company (the parent company)• Toyota North America
– Design & Manufacturing• 10 Plants• 8 Design/R&D Facilities• 1 HQ
– Sales & Distribution• 8 Vehicle Distribution Centers• 11 Parts Distribution Centers• 16 Regional Sales Offices• 3 Private Distributors• 1 HQ• TRD, AirFlite
– Toyota Puerto Rico, Canada, Mexico• Dealership Network (Toyota/Scion, Lexus)
– 1400+ Independent Franchises
Toyota Principles
• Eliminate Muda– “…any expenditure of time, money, material, effort, or
other resource that does not generate perceptible value for the customer.” – The Toyota Way
• Global Earth Charter (1992)– “Pursue production activities that do not generate waste”– “Participate in the creation of a recycling-based society”
• Respect for People• Kaizen (Continuous Improvement)• Metrics, Metrics, Metrics
Examples of Success
• 10 Plants “Near Zero Waste” (95% reduction of waste to landfill from a 1999 baseline)
• 1 HQ and 5 Distribution Centers that are “Zero Waste to Landfill”
• 12 Distribution Centers >90% Recycling Rate• Integration of Waste Management into ISO 14001
Environmental Management Systems• $1.3 million in net savings on waste management• Returnable shipping modules saved 9.4M pounds of
cardboard, 25.9M pounds of wood, and >$12.3M in costs.
Stages of Waste Management
Three Stages of Waste Management Programs1. Recycle Some2. Recycle More3. Recycle Less
Core Concepts
• Waste Streams
Waste Streams
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
Months
Po
un
ds
of
Mat
eria
l
Soft Plastic
Accum Restraints
Safety Restraints
Extra Recycled
Paper
Hard Plastic
Metal
Cardboard
Pallets
Recycle Some
• Stage 1– Starting from scratch– Move from all disposal to recycling
• Steps– Create Champions– Pick 3 Largest Waste Streams to Start Recycling
• “Awareness” Waste Stream (bottles & cans)– Establish Metrics
• Pounds Recycled• Recycling Rate• Cost savings
– Establish Awareness and Motivation
Awareness & Motivation
• Changing Bins vs Changing Minds• Do you know?
– Make it clear– Visual controls– Label well
• Do you care?– Need variety of motivations– Make the personal connection– Think Upstream– Also social benefits
Recycle Some
Toyota Examples• Starting Distribution Center programs
– Cardboard, Wood Pallets, Metal– ~80% of waste
• Dealership Assistance1. Assess your waste situation2. Select a recycling vendor3. Create a collection system4. Educate and train
Recycle Some
• Key take-aways– Establish Efficient Collection
• Use Visual Controls• Support the Work Process
– Give Feedback to Associates– Create Early Success– Start with More in mind
Visual ControlsVisual ControlsBlue = RecyclingRecycling = Blue
Visual ControlsVisual ControlsFloor MarkingsLabels EverywhereClear/Dark Bags
Visual Controls
Color codingPhoto cues
Clear Locations
Support the Work Process
Just-In-Time Recycling
Visualizable Feedback
26,000 Gallons of Gasoline
That's how much energy we've saved by providing recycled materials to industry.
That's how many trees weren't cut down due to our paper, cardboard, and wood recycling efforts.
900 Trees
That's how much water pollution we've avoided through recycling.
500 Pounds
Based on NERC/EPARecycling Benefits Calculator
Recycle Some
• Key take-aways– Establish Efficient Collection
• Use Visual Controls• Support the Work Process
– Give Feedback to Associates– Create Early Success– Start with More in mind
Recycle More
• Stage 2– First recycling is done– Adding rarer waste streams– Expanding complexity– Potential Trade-offs
• Steps– Create Experts– Assess what’s left in the trash– Assess what vendors are available– Add new streams as projects– Consider “waste pooling” for thin waste streams
Recycle More
• Toyota Examples– Adding Plastics Recycling– Separating Metals (Fe, Al, Cu, etc.)– Adding Composting– Windshield Recycling
Recycle More
• Key take-aways– Leverage Early Recycling– Re-evaluate Metrics
• Need for normalization• Accommodate diminishing returns
– Create density– Navigate Trade-offs
Recycle Less
• Stage 3– Generate less that needs to be recycled– Focus upstream– Reduce/Reuse
• Steps– Create Partners– Use your data– Look for reusable alternatives– Design away– Substitute materials– Inform purchasing decisions
Recycle Less
• Toyota Examples– Eliminating Styrofoam Packaging– Starting Returnable Packaging– Return Shipments/Reverse Logistics– Upstream Thinking
• Packaging Calculator• EPAT• EPEAT
– Supplier Returns
Recycle Less
• Returnable Packaging
Recycle Less
• TMS Milestone– 2009: Reduced more than Recycled!– Reduce/Reuse: 35.3M pounds– Recycle: 22.5M pounds– Landfill: 1.3M pounds
Recycle Less
• Key take-aways• Re-evaluate Metrics
– Recycling Rate isn’t everything– Disposal Rate
• Look Upstream– Buy to Reduce– Feed Information Upstream to Purchase Decisions
• Form Partnerships– Between Facilities– With Suppliers– With Other Companies
Conclusion
Three Stages of Waste Management Programs1. Recycle Some2. Recycle More3. Recycle Less
Conclusion
• Much can be done• There’s a lot of work to do
• More details available at:http://www.toyota.com/about/environment/
• Ryan [email protected]
• Questions?
