“Innovation distinguishes between a leader and a follower,” said Steve Jobs. Recently, I had the opportunity to spend three days at TOTO’s North American headquarters in Morrow, Georgia. TOTO’s manufacturing facility is a technological marvel and exemplifies the highest standards for sustainable manufacturing practices in the industry. It’s also the cleanest manufacturing facility I’ve ever visited.

TOTO was founded in 1917 in Japan by Kazuchika Okura to supply his country with plumbing products. In the early 20th century, Japan lacked public sewer systems on a national scale. Okura created a ceramic laboratory to develop solutions for Japan’s sanitation issues. TOTO’s mission was to improve the quality of life and change people’s perception of what a bathroom could be.

TOTO’s Motto

“Take pride in your work, and strive to do your best. Quality and Uniformity. Service and Trust. Cooperation and Prosperity.” TOTO’s motto inspires the company’s employees every day to do their best. This philosophical framework inspires their employees from the assembly line to the corporate boardroom.

Many companies create a motto, mission statement, or blurb that seems like a last-minute add-on for a website or brochure. Many companies suffer from a rudderless direction as they drift through the marketplace, the original founders have already retired or are dead. The fire that once propelled the manufacturer has been stifled by lack of innovation, maintaining the status quo, and only concerned with hitting monthly sales goals. But not TOTO…

TOTO’s Philosophy

There are several cultural differences between a Japanese company and an American company. Most American companies focus on ROI and don’t necessarily concern themselves how this is achieved as long as the financial results are positive. Many Japanese companies review the process of ROI.

TOTO’s philosophy is: “TOTO strives to create a great company that is trusted by people around the world and to contribute to the betterment of society.” The company establishes five components to achieve this goal.

• Create an enriched and more comfortable lifestyle and culture built on our plumbing products.
• Provide high-quality products and services through ongoing research and development.
• Create an employee friendly work environment that respects individuality.
• Pursue customer satisfaction by exceeding expectations with our products and services.
• Protect the global environment by conserving finite natural resources and energy.

All of these goals help make TOTO one of the most sustainable manufacturers in the world. These aren’t empty words to decorate and full up space on brochures. These goals are executed on a daily basis from the assembly line to the showroom.

TOTO’s Sustainable Manufacturing Practices

TOTO’s manufacturing plant in Morrow, GA is powered by solar energy. Aside from the natural gas kilns to make the ceramic toilets, the facility is powered by renewable energy. Water is considered a crucial resource by the company. In fact, Bill Strang, CEO of TOTO USA likes to say that TOTO is in the water business. The Morrow facility recycles 100% of the water used during production of the ceramic toilets and other products.

In 2017, established a set of global environmental goals that would seem lofty or even impossible for some manufacturers. TOTO committed to reduce the amount of water consumed during product use by 700 million m3. In addition, TOTO planned to reduce CO2 emissions during product use by 3.3 million.

Product Transparency

TOTO has developed product transparency documentation including Life Cycle Assessments and EPDs. The EPDs can contribute to points in LEED v4. More importantly they have helped TOTO identify where they could optimize their supply chain, production line, and transportation activities. Their EPDs are known as Transparency Reports and were developed with the help of program operator Sustainable Minds.

TOTO has also developed material health documentation such as Declare Labels. A Declare Label answers three questions: where does a product come from, what is it made of, and where does it go at the end of its life? Declare Labels are similar to Health Product Declarations (HPDs). Both product transparency documents serve as nutrition labels for products.

The Bottom Line

At the end of the day, manufacturers should walk the talk. I still see greenwashing from time to time in the marketplace. Some manufacturers have little or no faith in their products and peddle brochures and websites with inflated or false information about a product’s sustainable attributes. TOTO not only promotes their sustainability initiatives but often exceeds them.

If we as a society are to transform the built environment in a positive way for future generations, it is crucial that we manufacturer building products in a sustainable way. TOTO is to be admired and emulated. What sustainability practices does your company practice at your manufacturing facility? How does your company integrate sustainability into your manufacturing processes?