Waste Reduction and Resource Recycling
The Yamaha Group is engaged in the manufacture of a variety of acoustic and electric instruments, as well as other electronic devices and components used in automobile interiors. Naturally, we use a wide variety of raw materials, and we generate a wide variety of waste.
Given the nature of our business, we have established systems to reduce the volume of waste produced and perform recovery/separation to promote the most effective use of limited resources.
The total Yamaha Group domestic waste generated for fiscal 2011 amounted to 6,900 tons, which was a 2,600-ton reduction compared to the prior fiscal year. Of the amount reduced, 1,500 tons can be attributed to a change in accounting method from fiscal 2011 in which we stopped including recycled amounts at factories in calculations.
Meanwhile, waste going to land fill amounted to 0.07% of total waste generated, maintaining a zero-emission status for the Group*1
- *1 The Yamaha Group defines zero emissions as less than 1% of total waste sent to land fill.
Amount of Waste Generated*/Landfill Rate
- *Waste generated includes industrial waste, general waste (except that contracted by the government) and valuable items.
- Yamaha Corporation Headquarters and factories, and Yamaha Group manufacturing companies in Japan
Waste Risk Management
The Yamaha Group adopted a waste information management system within our Yecos environmental information management system in fiscal 2005. This marked a major step in reducing various environmental risks related to waste processing.
During fiscal 2010, we conducted a comprehensive review of our systems to improve management of waste disposal contractor selection, outsourcing contracts, manifests, and other related areas. In fiscal 2011, we began operations of a new system providing improved management precision with respect to the areas mentioned above.
We also integrated our ISO14001 management system throughout our domestic group. Our system rollout included our sales offices, where the system had mainly been used in manufacturing locations in the past. We monitor our status through internal environmental audits and other means, promoting waste management under a common set of Group standards.
Also during fiscal 2005, we began publishing waste data sheets (WDS) summarizing substance property and other information related to waste. This was another step in preventing accidents during the waste disposal process, and in ensuring proper disposal. With the cooperation of the waste management departments in our business locations, we were able to complete and publish WDS for all specially controlled industrial waste*2 during fiscal 2010.
- *2 Specially controlled industrial waste includes industrial waste products that may potentially harm human health or damage the environment due to explosive volatility, toxicity, potential for infection, etc.
Reducing Specially Controlled Industrial Waste in the Wind Instrument Manufacturing Process
Toyooka Factory, Yamaha Corporation
Yamaha's Toyooka Factory is working to reduce the levels of specially controlled industrial waste, including waste acids and waste alkali that are generated during the wind instrument manufacturing process. In November 2010, we put new vacuum concentration equipment into operation for targeted liquid waste. As a result, we were able to reduce output by 80% in fiscal 2011 compared to fiscal 2009. Total factory output amounted to 49 tons, meaning we achieved output of below 50 tons, the level set for high-volume emission businesses as defined in the Waste Disposal Law. Through these initiatives, the Toyooka Factory contributed to a significant reduction in the levels of Specially Controlled Industrial Waste throughout the Yamaha Group in Japan.
Vacuum concentration equipment
Waste Reduction and Advanced Organic Material Processing through Added Wastewater Processing Equipment
Kakegawa Factory, Yamaha Corporation
During September 2009, we installed more wastewater processing equipment to reduce waste and improve the disposal of organic matter at the Yamaha Kakegawa Factory. The additional equipment made it possible to treat wastewater (which includes glue that is left over from the piano manufacturing process) within the facility, every year we have reduced 900t of waste generated from fiscal 2010.
We also installed a Membrane Bioreactor*3 (MBR) behind the existing contact aeration vat of the wastewater treatment system, which has led to more stable wastewater processing.
Additional wastewater treatment equipment
- *3 A method using a membrane (usually a microfiltration membrane) for solid-liquid separation of activated sludge. Benefits of this method include the fact that no settling tank is needed, there is no bacteria coliform or suspended particulates in the processed water, and that the high concentration of mixed liquor suspended solids allows for quick processing.
Effectively Using Wood Scrap
The Yamaha Group is making better use of the wood scrap that is a byproduct of the manufacturing process. At the Yamaha Kakegawa Factory, we sell wood scraps (scraps cast off from the wood cutting process) to building materials manufacturers, who use the scraps as raw materials for hardboard. Hardboard is produced by further cutting up the wood scraps, breaking them down into fibers, and then agitating in water. The mixture is heat-pressure molded into boards. Hardboard offers superior workability, including die processing and bending. Hardboard is also an environmentally friendly recycled product, designated under the Green Purchasing Law. Hardboard is used in building interiors, furniture, as industrial materials, and in various other applications.
Wood scraps segmented for sale
Hardboard Production Method
Other Case Studies
(1)Reusing wood scrap from piano shipping materials (skids) as planters for Green Eco-Curtains
Repeated use during piano shipment
Skids after useful life is over
Used in Green Eco-Curtains
Planters made from skid scrap wood
(2)Pelletizing sawdust for use as fuel, pet litter
|Briquettes made from sawdust left over from the piano manufacturing process||Pet litter (cat litter) made from sawdust briquettes|
(3)Commemorative products for factory visitors made from wood scrap
Coasters made from guitar sound hole cutout scrap
Key chains made from piano hammer ends
Wood from marimba keys shaped into chopsticks