DENSO Manufacturing U.K. Limited

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A supplier of automotive technology, systems and components for the world’s major auto-manufacturers (as well as consumer and industrial products developed from the company’s experience in the automotive industry), DENSO Corporation operates in 32 countries and regions across the globe, employing around 120,000 staff throughout its total operations

As part of the Group, DENSO Manufacturing U.K. Ltd. manufactures air conditioning units and cooling systems in its 700 employee Telford site (Shropshire). A key part of the environmental commitment is the DENSO Corporation EcoVision 2015 policy. Drawn-up in November 2005, the policy provides detailed analysis of where and how the company should reduce its environmental impact across a wide range of areas, from energy efficiency to waste water management. Manel Roura, Environmental Officer at DENSO Manufacturing U.K. Limited, explains that possessing “a strong corporate environmental policy with challenging objectives and targets” such as EcoVision 2015 is the first and most important step the company has taken to reducing its environmental impact.

The policy also sets out guidelines for taking environmental performance into account in a series of development and design considerations specific to the automotive manufacturing processes undertaken by DENSO Group Companies. This includes a design review system for “preliminary evaluation of environmental effects in development and design processes”, as well as to achieve a wider-scale reduction in environmental impact for DENSO Group activities. “Integration of the environmental activities into the manufacturing activities has been key to the reduction of our environmental impacts”, says Roura.

The company is also aiming to enhance its environmental communication – thus increasing overall transparency – by disclosing environmental information to all stakeholders and communicating with regional communities in which work takes place.

DENSO Manufacturing U.K. Limited’s work on waste reduction has also proved extremely successful, and was recognised in 2009 by a Green Business Award. This was partly due to some of the measures implemented by an ‘environmental champions’ group, first established within the company in 2004. The group was tasked with reducing raw material use, improving energy conservation and energy reclamation, and waste water management.

The environmental champions group helped to develop work on DENSO Manufacturing U.K. Limited’s waste classification, which saw a reduction in the amount of waste going to landfill, from 55 tonnes every month to zero. 94% of the company’s waste is now recycled and the remaining 6% is incinerated, some of which is used for energy recovery.

The company set itself various ambitious targets to fulfill the goals set out in its waste management programme, resources management programme and EcoVision 2015, including: to achieve zero landfill in all manufacturing sites worldwide; a 2009 waste reduction target of 10%, in both total waste and hazardous waste, and a 5% reduction in non-recyclable/general waste; and to introduce returnable packaging to collect and dispose of hazardous waste for incineration.

A number of steps were then taken to achieve these targets, including the following: reworking rejected parts to reduce production scrap; implementing internal procedures for waste packaging in pallet management, and working with suppliers to increase returnable packaging; training in resource efficiency was provided to the environmental champions, who now manage ‘waste mapping’.

The results of these methods were extremely positive, with significant environmental improvements noted, including a reduction in hazardous waste and cost savings of £172,000 through energy efficiency initiatives. Zero landfill was also achieved through the work, as Roura explains: “Achieving zero landfill required a very comprehensive programme of activities, but the most important starting point was the top management commitment to achieve the target. Activities included a detailed analysis of waste generated on site, implementation of a system for waste segregation, continuous monitoring of waste segregation through audits and a large programme of communication including awareness campaigns.”

Additionally, reducing the amount of waste generated also meant that use of vehicles to transport the waste, emissions from incineration and energy used in waste recycling processes were all lowered.

Recycling and waste management are also crucial elements of a wide-ranging staff engagement plan at DENSO Manufacturing U.K. Limited – an area which Roura cites as key to reducing the company’s environmental impact. The engagement process takes a number of forms, as Roura explains: “We run regular environmental campaigns, including a Christmas card-recycling campaign in January and World Environmental Week in June. Initially, our campaigns were focussed on recycling but currently we have included many more elements of sustainability: energy saving, resource efficiency, transport, and biodivesity. We also have a group of environmental champions that drive all environmental activities in every area.”

Other measures that the DENSO Group is taking at various plants across its global operations include: installation of combined heat and power facilities (which will reduce carbon emissions by using waste heat for air conditioning and cooling); monitoring hourly energy use of machinery, in order to address the biggest energy consuming equipment and also measure progress; using a ‘DENSO total energy control system’, which optimises energy use and management by offering central control of co-generation and other energy power systems and equipment; rationalising of logistics operations, such as customising shipping schedules and routes to match optimum freight volume and loading requirements, meaning that journeys are fewer and more efficient, which lowers carbon emissions; and renewable energy generation technologies, including micro wind power and solar photovoltaics.