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Indian automotive sector: in pursuit of sustainability

WriteCanvas News


The automotive and auto ancillaries industry in India contributes $70 billion or 2.1% to the national GDP, and employs 5 million people.

While the sector accounts for 4.5% of India’s merchandise exports, it is also responsible for 1.4% of the country’s annual greenhouse gas emissions. Implementing sustainability priorities could help India achieve net-zero emissions.

These are the findings of a new The Automotive Component Manufacturers Association of India (ACMA)-McKinsey study titled: Mobility 360° – Sustainability for competitiveness: A perspective on sustainability in the automotive sector.

OEMs worldwide set upstream decarbonization targets, requiring suppliers’ interventions, especially for Scope 3. India’s automotive companies commit to decarbonization, with use-phase emissions potentially dropping as electric vehicle adoption rates rise.

Key findings:

  •  Sustainability is a priority for most Indian OEMs
  • Controlling Scope-1 and -2 emissions primary focus
  • Encouraging suppliers on sustainability themes to reduce Scope-3 upstream emissions
  •  Many OEMs are adopting targets, measuring and tracking key performance indicators and disclosing ESG information
  •  While 100 per cent disclosure on ESG reports is still some way off, the journey has begun

Some stats:

  1. 3/4  OEMs list sustainability among their top 5 business KPIs
  2. 2/4 OEMs are working with suppliers to change designs for circularity
  3. 3/4 OEMs disclose ESG information in their annual report/BRSR report
  4. OEMs are already rolling out RFQs incorporating decarbonization targets

Indian OEMs are currently where EU players were a few years ago OEMs’ demand for sustainable operations may suddenly change as policies change. Indian suppliers could kick off efforts to be better prepared for these changes, to become preferred suppliers for OEMs in the future, the authors noted in the report.

Offense vs defense:

Playing defense in the global sustainability push can lead to a growing capital cost, declining market share, and reactive mode. On the other hand, companies can play offence, resulting in a 20-30% valuation increase and increased strategic distance from competitors. This strategy relies on five drivers:

  • Chasing new business opportunities: Companies could build new green businesses by tapping into existing assets, capabilities and relationships.
  •  Targeting sustainability qualification-led–led growth: Offering green products that match customer expectations (e.g., green packaging) and requirements (e.g., carbon neutral steel) could lead companies to command a higher premium in the market.
  • Achieving sustainability-led cost reduction: Thoughtful use of resources such as energy, water, waste and raw materials could help improve resource efficiencies.
  • Improving employee productivity, well-being and morale: Companies could implement a holistic strategy for employee engagement to cut down attrition, boost sales productivity, and control absenteeism as employees feel rejuvenated and inspired by their organization.
  • Growing valuation impact (equity): A compelling sustainability story and credible strategy could drive up valuation and expand multiples.

Material circularity, renewable energy, decarbonization:

Material circularity in the automotive sector can increase the industry’s top line by 10-20%, reduce costs by 5-10%, and decrease CO2 emissions by 50-70%. India’s automotive sector is promoting circularity due to policy and regulatory support, high primary material prices, and increased carbon markets. Recycled materials require less energy and reduce geopolitical risk.

The report noted that auto-component manufacturers in India primarily rely on electricity for manufacturing and assembly processes, accounting for 90% of their energy needs. However, a shift to renewable energy sources is crucial as grid electricity is the primary emission source. Between 2019 and 2022, thermal sources accounted for 74% of the total electricity generation mix. Solar and wind energy accounted for 11% of the mix in 2022. Alternatives for energy decarbonization include behind-the-meter solar, captive renewable energy access, and energy efficiency improvements. Companies can also consider gas-based, bio-mass-based, solar, hydrogen, or electric boilers.

Respondents from the auto suppliers segment indicated new business opportunities, sustainability qualification-led growth and sustainability-led cost reduction as the three most relevant themes.

The journey of automotive companies and their suppliers to reduce emissions calls for a focus on two big themes.

  1. A concerted effort towards energy decarbonization by mapping the greatest sources of emissions (electricity, steam, backup power, etc.) and finding scalable, cost-efficient alternatives to these.
  2. A quest to attain material circularity – with sound decisions about material sourcing, product design, process selection, and associated logistics management to ensure an overall sustainable value chain for automotive companies.

The role of the stakeholders:

Sustainability is becoming mandatory for operating licenses, but implementing it requires industry alignment, cross-value chain partnerships, and collaboration with stakeholders. The government can support this by strengthening reporting regulations, introducing incentives, tax benefits, and grants, and promoting circular-economy principles. Automotive industry bodies can create a scalable sustainability framework, drive capability-building programs, and facilitate collaborations. OEMs can support domestic suppliers by setting ambitious decarbonization targets, adopting renewable energy options, and designing products for circularity. Suppliers can be at the forefront of this transformation by moving sustainability closer to their business priorities, investing in energy transition initiatives, and working with OEMs to drive circularity.


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How Honda is speeding toward circular materiality?

Sonal Desai


In line with the UN SDG 12 on Sustainable Consumption and Production (SCP), auto manufacturer Honda has pushed on its accelerator toward circular materiality.

The company is advancing a recycling initiative that takes uniforms worn by associates and textile waste from its U.S. manufacturing and R&D facilities and transforms them into sound-absorbing insulation for use in Honda and Acura automobiles.

The initiative:
The Honda uniform recycling program leverages cross-industry collaboration between Honda and its uniform suppliers Aramark and Cintas Corporation, as well as insulation supplier UGN Automotive and textile recycler Leigh Fibers. Uniforms from Honda production and R&D facilities in Alabama, Indiana, North Carolina and Ohio are recycled and reused in five different insulator parts on all nine Honda and four Acura models made in North America. In the future, Honda plans to expand the uniform recycling program to other facilities in North America.

The process:
The effort is a part of Honda’s Triple Action to Zero approach which focuses on resource circulation to make new products from 100% sustainable materials toward its resource circulation goal of making new products from 100% sustainable materials by 2050, the company said in a press release.

This program diverts approximately 45,000 pounds of uniforms from reaching landfills each month. To maximize end-of-life material recycling, the uniforms are shredded into fibres and repurposed for insulation in new Honda and Acura automobiles. The program reduces waste to landfill from the company’s manufacturing and R&D facilities. More than 380,000 pounds of uniforms have been recycled since the program launched at the end of 2021, the company said.

The transformation:
Uniforms designated for reuse in Honda and Acura vehicles are baled and sent to Leigh Fibers where they are shredded into material that can be used as vehicle insulators. After extracting zippers and buttons, the material is blended and reprocessed, it is delivered to insulation supplier UGN. UGN blends, consolidates and trims the fibres into material that is moulded into insulation and returned to Honda auto manufacturing plants for new vehicle production.

Executive quotes:
Rob Long, Senior Procurement Specialist, Honda North American Indirect Procurement: “Collaborating with Honda suppliers in the uniform recycling program has brought great value to our supply chain sustainability efforts. As Honda works to advance sustainability, we appreciate our suppliers’ efforts to innovate their business operations to reduce waste and give new life to our Honda uniforms.”

Negar Gilsinger, Manager, Resource Circulation, American Honda Motor Co: “To achieve our Triple Zero goal of 100% sustainable material use, we need to take every possible opportunity to recycle materials at end of life for reuse in our products, thereby minimizing our utilization of virgin materials. By maximizing end-of-life material recycling, we are giving our uniforms a second life in Honda and Acura vehicles.”

Pranav Singh, Director, Purchasing & Packaging, UGN Automotive: “It is part of UGN’s history and culture to maximize recycled content in our parts, reduce landfill by recycling our own by-products, and promote circular, mono-material technologies that enable end-of-life vehicle recycling. Reusing Honda uniforms contributes to these efforts by increasing the amounts of recycled materials available for insulators and opens the door to other post-consumer textile waste projects.”

Background:
Honda’s uniform recycling program builds on the company’s longstanding commitment to reduce waste and incorporate higher recycled content in Honda and Acura vehicles. The initiatives include:
• Working with suppliers to transform post-industrial textile scrap, such as fibres from denim, into vehicle insulation/absorption material.
• Reusing in collaboration with UGN, approximately 2,800 tons of recycled post-industrial textile waste – equivalent to 5.6 million pairs of jeans – and 3,000 tons of post-consumer PET (polyethylene terephthalate) bottles – equivalent to 6 million water bottles for vehicle sound-absorbing insulation.
• Using soybean-based foam for vehicle headrests, recycled plastic water bottles and recycled Honda car bumpers for wheel liners, plant-based material for the seat fabric.


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