In 2006, we began switching our data collection over to the European waste classification system, which is a good fit for our waste streams and will allow improved benchmarking and comparison. These enhancements are part of our overall Global Emissions Manager database launch. Our data-collection process improvements will help our facilities continue to develop new methods of reducing and better managing waste. More extensive results will be published in future reports when year-over-year trend data are available.
Our facilities continue to reduce waste and improve its management. For example, Ford's Livonia (Michigan) Transmission Plant eliminated virtually all regulated hazardous waste generation. The Livonia plant was regulated as a "small-quantity generator" due to its generation of wastes from solvent-containing paint and a waste from the plant's heat treat process.
With the help of Ford's environmental experts, plant managers and workers in the painting and heat-treating functions worked together to identify alternatives to the use of solvent-based paints and process modifications that would eliminate hazardous waste generation from the plant.
Following a one-time effort to use up and dispose of solvent-based paint, Livonia switched to purchasing only water-based paints, working cooperatively with the paint vendor. The team conducted trials to ensure the alternative paint would serve the needs of the plant.
The team also identified changes to the process of cleaning "salt quench" tanks that made the material removed suitable for recycling, rather than disposal.
The zero hazardous waste approach eliminates potential risks, reduces regulatory requirements and saves disposal costs.
Other waste reduction projects include the following:
- Implementation of a minimum-quantity lubrication system for machining at the Livonia Transmission Plant. An industry first in North America for high-volume powertrain production, the system uses a precisely dosed oil mist in place of multiple gallons of metal-working fluid. The metal chips created during the machining process are removed from the work zone by a vacuum extraction system and subsequently recycled. The system results in a cleaner work environment, reduction of the machining fluid waste and increased metal recovery. It also extends the life of the machining equipment and saves money compared to traditional processes.
- Ford's Sharonville, Ohio, transmission plant provides an incentive to its waste management contractor to achieve at least 5 percent waste reduction each year. The Sharonville plant recycles dozens of waste materials. For example, the plant recently began recovering shot blast pellets, the small steel balls used to take edges off of metal parts, in addition to the steel dust created by shot blasting.
- The Michigan Truck Plant has run tests using paint waste as a filler in a liquid sound-deadening material that helps keep vehicle interiors quiet.
