Canadian Autoparts Toyota Inc.

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"Making energy efficiency part of our commitment to continuous improvement has resulted in energy savings worth $110,000 since 2003 – with more to come."

— Gary Smallenberg, President, Canadian Autoparts Toyota Inc.

The situation

Established in 1983, Canadian Autoparts Toyota Inc. (CAPTIN) is a parts manufacturer for Toyota Motor Manufacturing North America Inc. (TMMNA). Some 237 staff, working in CAPTIN's Delta plant, produce approximately 1,200,000 aluminum wheels annually for Toyota vehicles.

Consistent with Toyota's strong commitment to the environment, CAPTIN has adopted "Kaizen," a team-oriented philosophy of continuous improvement that governs all of its activities. This philosophy is put into action through a unique "treasure hunt" process. Every few years, a team from TMMNA visits the CAPTIN plant to join with its energy team in conducting an energy "treasure hunt." Together, both groups blend their knowledge and experience to identify cost-saving energy ideas and to renew awareness of and enthusiasm for energy use reduction.

Over the years, the combination of "Kaizen" and the "treasure hunt" has resulted in numerous plant-wide improvements and improved environmental performance. Still, CAPTIN was looking for even greater energy savings and efficiency improvement.

The solution

Initiatives

CAPTIN approached BC Hydro for assistance and, in 2002, Power Smart energy experts conducted an industrial energy study. The experts even joined the CAPTIN team in conducting their "treasure hunt" in 2004. Many potential energy-saving initiatives have been identified and several of these projects have been implemented, including:

• Retrofitting office and plant lighting from T12 to T8 fluorescent technology, and installing occupancy sensors
• Connecting HVAC units and the plant's lighting system to an expanded control system for more efficient operation
• Optimizing the compressed air system

CAPTIN has also made operational improvements that have resulted in additional energy savings. An energy management team meets weekly to review energy saving opportunities. The company adopted a zone management approach in which all team members are responsible for reaching annual energy and environmental targets, and receive bonuses for doing so. Putting its environmental principles into action, CAPTIN also purchased Green Power Certificates two years in a row.

Thanks to these initiatives, in 2004 CAPTIN managed to improve its electricity usage by 5% – while increasing production by 14%. CAPTIN has pledged to improve its energy consumption an additional 5% next year.

In recognition of CAPTIN's commitment to continuous Power Smart improvement and its innovative approach to energy management, BC Hydro has designated Canadian Autoparts Toyota Inc. as B.C.'s first Power Smart Certified manufacturer.

Its sixth plant expansion, which will boost wheel capacity by 17% to 1.68 million units per year, started in 2007. Continuing its tradition of increasing production while still decreasing energy use, CAPTIN is using Power Smart's New Plant Design program to optimize energy efficiency in the new space.

The benefits

Electricity savings
Since 2003, energy efficiency upgrades helped CAPTIN save approximately four gigawatt hours of electricity, or $110,000, while increasing production by 14%.

Greater awareness and support for energy efficiency
CAPTIN's team-oriented approach to continuous improvement means that employees at every level take responsibility for identifying and implementing energy-saving opportunities.

Reduced environmental impacts
CAPTIN's increased energy efficiency of its operations and purchase of green power certificates support the development of clean, renewable energy in B.C., and result in fewer impacts on the environment.