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Environmental Stewardship Initiative

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Title: Environmental Stewardship Initiative


1
Environmental Stewardship Initiative The GKN Way
2
GKN Driveline Sanford Precision Forming Facility
  • Plant construction 1983
  • First production October 1984
  • Inital capacity of plant 4 million forgings /
    year
  • 2005 output more than 12.2 million forgings

3
Our Product
Steel is the starting material
From forgings, CV joints are made at other GKN
plants
Forgings are made at PF
GKN has more than 40 of the global market for CV
joints
4
HR-EHS-014 / January 2, 2001 / Rev. Date 5/5/04
5
OUR SIGNIFICANT ENVIRONMENTAL ASPECTS IMPACTS
ENERGY CONSUMPTION
WASTE GENERATION
WATER CONSUMPTION
ISO14000 ENVIRONMENTAL MANAGEMENT SYSTEM
6
Corporate Target
Site Target
Corporate Target
Site Target
Corporate target 10 reduction from 1999
baseline Site target 18.65 reduction from 1999
baseline
7
Corporate Target
Site Target
Corporate target 10 reduction from 1999
baseline Site target 17.75 reduction from 1999
baseline
8
Corporate Target
Site Target
Corporate target 5 reduction from 1999
baseline Site target 48.14 reduction from 1999
baseline
9
Our Commitment beyond Compliance
10
Earth Day Celebration
Employees reviewing Earth Day displays
An opportunity to renew our pledge to minimize
the impacts of our significant aspectsenergy,
water, and waste
11
State-of-the-Art Emissions Control System
The Rotoclone scrubber combines centrifugal force
and mixing of water and dust-laden air
Only forging plant in the world that has applied
this technology to control warm form press
emissions
Rotoclone scrubber replaced the wet scrubber
system although compliance was fully achieved
with the wet scrubber system
12
Debottlenecked Waste Water Treatment Plant
The limitations of the previous plant were flow
and zinc content. But the new plant was
over-designed on purpose to accommodate
stewardship features, e.g., drier filter cake,
lower toxic levels, and equalized flow.
The Waste Water Treatment plant project was
debottlenecked to ensure zero non-compliance at
all times
13
Value Stream Management (VSM) Cell
The VSM cell reduced material movement by
streamlining the cold forming operation
Phosphate treatment is one of the main
contributors of environmental pollution. The VSM
cell eliminates phosphate treatment.
The VSM cell results in significant reduction of
energy, water, and wasteour significant ISO
14000 aspects and impacts.
14
Recycling Projects
COMPLETED
  • Computer and photocopier paper
  • Plastic bottles
  • Aluminum cans
  • Chemical drums
  • Aerosol cans
  • Used oil
  • Wood pallets
  • Fluorescent lamps
  • Steel scrap

15
Other Stewardship Initiatives
  • GKN is one of the few companies that tracks CO2
    emissions from transportation of raw materials
    and products (Global Warming/Kyoto Protocol)
  • We meet with the City of Sanford to pro-actively
    address compliance issues
  • Various parameters of our storm water are
    monitored on a daily to weekly schedule (our
    permit requires semi-annual monitoring only)
  • We are actively pursuing a project for
    incorporating waste water treatment sludge into
    building materials (instead of landfilling)

16
Our Partnership with Local Community
17
Sustainable Development
ENVIRONMENT
ECONOMY
GKNS CORPORATE POLICY EMBRACES HARMONY BETWEEN
THE ENVIRONMENT, THE ECONOMY, AND THE COMMUNITY
COMMUNITY
18
Greening Sanford
GKN Driveline employees planted trees at Depot
Park, Sanford (Sanford Herald, April 17, 2005)
19
Benchmarking for Environmental Stewardship
The GKN PF plant is routinely benchmarked by
forging operations all over the world We have
benchmarked environmental management systems of
Toyota, Moen, and others In return our
environmental management system was benchmarked
by NACHI, Lee Iron and Brick, Caterpillar, and
others Our corporate website provides internal
benchmarking opportunities on our best management
practices for environmental systems
20
Other Community Initiatives
  • Presentation of our environmental policy and
    environmental management system to the Mayor and
    his City Council members
  • Partnership with NC State University on energy
    audit
  • Partnership with NC Solar Center, State Energy
    Office, and San Diego Power for energy reduction
    measures
  • Partnership with supplier IMDS program for
    greening the supply chain

21
Integration of our EMS into Core Business
Functions
22
Integration Efforts
  • Energy, water, and waste evaluations in our
    capital investment decisions (e-works software
    for CAPEX decisions)
  • Kaizen (continuous improvement) initiatives that
    won top award for EHS innovation in 2002, and
    local management award in 2003 and 2004
  • Communication of ISO 14000 objectives and
    targets
  • Monthly meeting with local management
  • Monthly meeting with top management
  • Quarterly environmental report to corporate
  • Annual environmental report to corporate

23
Integration Efforts
Site environmental goals and objectives are
integrated with corporate loss prevention and
risk assessment approach (through use of
corporate-sponsored ENGAGE software) Corporate
Green Scheme program fosters innovation in
environmental management systems, and provides a
significant opportunity for benchmarking best
management practices Quarterly and annual
environmental reports are submitted to corporate
addressing environmental management system
conformance with ISO 14000 standards
24
Integration Efforts
  • ISO 14000 steering committee, non-conformance
    forms, behavioral surveys
  • ISO 14000 training and awareness campaigns
  • ESCARs (corrective and preventative actions
    program)
  • Rewards and recognition program
  • Partnership with suppliers and contractorsreview
    of EMS information at the security gate,
    contractor video

25
Incentives for Meeting Objectives and Targets
  • Bonus package for management is linked to meeting
    ISO 14000 objectives and targets
  • Incentives package for employees is linked to
    overall achievement of EHS metrics (including ISO
    14000 objectives and targets)
  • Spot awards for submitting exceptional
    environmental recommendations for meeting ISO
    14000 objectives and targets

26
Going into the Future…..
  • More recycling projects Toner cartridges,
    Batteries, Oil absorbents, Gloves, Aprons
  • Carpooling
  • Further awareness through ISO 14000 puzzles and
    behavioral surveys
  • Water-based parts cleaners (instead of
    solvent-based)
  • Kamishibai audits for our environmental system
  • Green supply chain

27
  • The GKN Driveline facility is poised to be the
    environmental benchmark for other GKN facilities,
    and for forging operations around the world
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