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 2012 amounted to 6,000 tons, which was an 800-ton reduction compared to the prior fiscal year. A change in tabulation method in fiscal 2011 meant that the amount of recycling inside factories was not recorded as waste generated, which led to a significant reduction (1,510 tons).

  Meanwhile, waste going to land fill amounted to 0.22% 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

Amount of Waste Generated*/Landfill Rate

  • * Yamaha Corporation Headquarters and factories, and Yamaha Group manufacturing companies in Japan
  • * Values for previous fiscal years revised.

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
Vacuum concentration equipment

Concentrated sludge
Concentrated sludge

Amount of Specially Controlled Industrial Waste (Yamaha Group)

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. In order to respond to the increase in processing, we renewed traditional wastewater treatment facilities in September 2012 to enable treatment of wastewater from the new processes. At the same time, we increased wastewater treatment capacity by around five-fold, including for adhesive agents. As a result, we were able to process this waste internally, which led to a reduction in waste of approximately 270 tons annually.

  In addition, we worked to make effective use of equipment such as by reusing idle equipment from other factories as equipment for wastewater processing facilities.

Wastewater treatment facility at the Kakegawa Factory
Wastewater treatment facility at the Kakegawa Factory

  • *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.

Reduction and Effective Utilization of Process Waste

  Yamaha Fine Technologies Co., Ltd. is working to reduce process waste*4 in the production of car parts. The company placed emphasis on improving faulty equipment and defects, the cause of process waste, in fiscal 2011, strengthening equipment maintenance, managing process waste data and introducing quality-related education through a standardized program. As a result, the ratio of process waste*5 was reduced by 56 points, exceeding the target of a 6-point reduction, and the amount of waste generated from the entire factory was reduced by 16%. Productivity increases with a reduction in process waste, which leads to greater efficiency in energy and resource use.

  • *4 Defects in work processes
  • *5 Proportion of process waste to the number of production units

Time-based management of process waste generated (using production analysis board)
Time-based management of process waste generated (using production analysis board)

Employees are taught about quality using a standardized program (This photo shows OJT related to passing along skills in inspection)
Employees are taught about quality using a standardized program (This photo shows OJT related to passing along skills in inspection)

  Yamaha Kagoshima Semiconductor Inc. worked to effectively utilize waste oil through recycling in fiscal 2012. Waste oil that was previously treated as industrial waste subject to special control was separated for its recycling potential and around 10 tons was effectively utilized as fuel for the year.

  Yamaha Corporation's Toyooka Factory has been making efficient use of waste, including rare metals, since fiscal 2011. Waste containing rare metals generated from the Research and Development Department, which was previously outsourced for waste processing, is now sold to outside contractors for refining and recycling, which has led to effective use of resources.

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
Wood scraps segmented for sale

Hardboard Production Method

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
Repeated use during piano shipment
Skids after useful life is over
Skids after useful life is over
   
Used in Green Eco-Curtains
Used in Green Eco-Curtains
Planters made from skid scrap wood
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
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
Coasters made from guitar sound hole cutout scrap

Key chains made from piano hammer ends
Key chains made from piano hammer ends

Wood from marimba keys shaped into chopsticks  
Wood from marimba keys shaped into chopsticks

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