Completed in 2009, Sharp Green Front Sakai is the new driving force behind Sharp’s efforts to join the green revolution in manufacturing
INTEGRATED: The energy control centre monitors utility usage in real time, cutting down on energy wastage and maintaining quality. (Inset) Takashi Okuda
OSAKA: If a corporation was given the chance to ‘reset’ and ‘redo’ its manufacturing and production methods, then Sharp Corporation’s (Sharp) Green Front Sakai would be the result.
Covering an area of 1.27 million square metres, the LCD and solar panel factory is approximately 28 times the size of the Tokyo Dome.
It is also the prime example of how efficiency, cuttingedge technology and ecoconservative methods can epitomise all of Sharp’s future technological and business ventures.
Despite the harsh economic conditions in Japan over the last few years, Sharp made the bold move by changing its business model towards ‘local production for local consumpt ion’ and by investing 430 billion yen (about RM16.04 billion) into building the state-of-the-art green factory.
They began construction in November 2007, finished it in October 2009 and started shipping out in the same month.
Sharp redefined its corporate vision in November 2009 when it put together the Sharp Biodiversity Initiative.
“Our business visions included contributing to the world with an environmental and heal th conscious business focusing on energysaving and energy-creating products,” explained Takashi Okuda, the executive officer of Sharp’s emerging markets division recently.
“Sharp Green Front Sakai will bring the world two environmentally friendly products: energy-saving LCD panels and energy-creating solar panels.”
When it declared itself as an ‘Eco-Positive’ Company, Sharp set itself out to cooperate with all stakeholders that make positive impacts on the environment.
While they attest that their ‘Eco-positive’ company does not mean that they have no negative impact on the environment, it does strive to be the most environmentally-sound manufacturing company within and without.
The production processes are simpler, thereby lowering production costs.
“Unlike conventional energy control methods where electricity, gas and water were controlled and supplied separately at each plant, the energy management centre in Green Front Sakai is the central nervous system that monitors and supplies energy use in real time throughout the entire facility,” said Okuda.
What results is a significant cut on energy and resource usage as carbon dioxide emission can be reduced to 48,000 tons per year (approximately 20 per cent reduction) while also contributing to the operation’s overall stability.
From production planning to process management and shipment, the plant’s IT conference system connects all 19 of its subsidiary compa nies together. The interbuilding transport system of their factory also precludes the need for trucks, thereby cutting down on excess logistics and preventable pollutants.
By cutting down on greenhouse gas emissions through both production and utility equipment, the 10 plants of Sharp Corporation were able to reduce carbon dioxide emissions by six per cent in fiscal year 2009 compared with the previous fiscal year and by 22 per cent compared to fi scal 2007 levels.
On the industry complex front, 100,000 energy-effi cient light emitting diode (LED) lights are used for all indoor and outdoor lighting throughout, making for approximately 80 per cent less consumption of electricity, not to mention the complete omission of mercury, infrared or ultra-violet rays that can be harmful to both environment and its workers.
Although the bulk of the plant is complete, Green Front Sakai is slated to complete the installation of its large-scale photovoltaic power generation system on its rooftops and other spaces.
This feat would not be a longshot for this company – it has been manufacturing solar panels since 1953 and has already signed an agreement with Natural Energy Development Co Ltd to install one of the world’s largest solar power generation plants in Thailand with a capacity of 73 megawatt. IT is a compact solution that gives Sharp Corporation the best of both worlds: ecological awareness, costeffectiveness and quality.
“The thin-fi lm solar cell plant in Sakai will serve as a model plant for futureSharp thin-fi lm solar cell plants around the world. Sharp will continue to accumulate and enhance its proprietary production technology and its knowhow, to meet the world’s growing demand for solar cells,” added Okuda.
The LCD panel plant is the fi rst in the world to employ 10th generation glass substrates. Using Sharp’s proprietary UV2A photoalignment technology, the plant produces high-contrast panels offering outstanding energy effi ciency in screen sizes of 40 inches and larger. These panels have been highly rated by LCD TV manufacturers around the world. The plant is currently in full operation, running at an input capacity of 72,000 substrates per month.