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Toyota Motor Engineering & Manufacturing North America, Inc.

Erlanger, Kentucky

ENERGY STAR Partner of the Year - Sustained Excellence

Toyota Motor Engineering & Manufacturing North America, Inc., serves as the manufacturing headquarters for 14 vehicle, engine, and parts plants that employ more than 35,000 Team Members. Toyota's success is due to an exceptional energy management system supported by the commitment of its Team Members to continuous improvement. This is the sixth time Toyota has received ENERGY STAR recognition. Key accomplishments include:

  • Developing successful new strategies to drive absolute energy use down by 17% in spite of market contractions and energy reductions already achieved in recent years. The company studied ways to reverse the ratio of variable to fixed energy in the assembly process while several of the company's assembly plants re-tooled or were under construction.
  • Continuing to identify new methods for reducing energy consumption in paint and casting operations through customized energy analysis of key production machines among the company's lines and plants. A reduction potential of 400,000 MMBtu has been identified to date and work is ongoing to capture noncapital-dependent improvements.
  • Educating more than 20% of the key Tier 1 supply chain on Toyota's "Treasure Hunt" process; to date an estimated 50,000 MMBtu in savings have been identified in supplier operations. 
  • Undertaking a complex study of alternative humidification technology in paint air make-up to eliminate the need for steam generators, an inefficient process. A pilot study of one air make-up unit shows savings of 15,000 MMBtu; Toyota will be able to apply this across its assembly plants. 
  • Engaging employees from all manufacturing sites in the Toyota "Race for the Green," a new competition in 2009 designed to "drive down" plant shutdown energy. 
  • Sharing Toyota's approach to industrial lighting improvement among ENERGY STAR industrial partners, including small- and medium-size companies throughout the United States.