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EPA RRC_workshop_3/08.ppt 1

GEP

GM Global Environmental Programs

General Motors CompanyBy-Product Management Program

Ohio State UniversityBy-Products Synergy Meeting

October 21, 2009

John Bradburn

Global Environmental Programs

General Motors Company


GEP


•Resource Management (RM)•Global By-Products Initiative•Zero Landfill•By-Product Summaries•Next Steps

•Design for the Environment (DfE)•GMR2 •Multimedia Processes

Agenda


GEP


Resource Management Overview:

Resource Management is an effective system which: (Benefits)

Reduces landfill waste and overall costs while increases recycling

Increases supplier responsibility for total system management

Provides incentive for suppliers to dispose of less, not more

Establishes team relationship with supplier

Commonizes procedures

Manages changing technology


GEP


Resource Management

Definition:

Rather than paying a waste contractor to dispose

of materials, GM engages a supplier, or resource

manager, as a partner inside the plant.

A single resource manager in each facility uses

on-site staff to handle all applicable aspects of

the waste business– focusing on waste

elimination first, then reduction and recycling,

and finally disposal.

The resource manager receives financial

incentives for finding innovative ways to

eliminate waste created during the manufacturing

process.


GEP


History - Resource Management

1994 – First GM Plant Implemented – Opel –Kaiserslautern

1997 – First U.S. Plant implemented Resource Management – Orion Assembly

1998 – First Non-Manufacturing Facility – Tech Center

2006 – Implemented in every GM Manufacturing facility in the U.S. and most Non-Manufacturing Facilities

Global Implementation Fully implemented in Europe

Other Regions various stages of implementation


GEP


LEVEL V

* Disposal

* Hauling

* Consultation

* On-site Management Team

* Off-site Support

* On-site Checks

* Development Programs

* Total System Analysis & Tech. Support

* Source Separation Program

* Recycling Center Search

* Environmental Reports

* Waste Elimination, reduction, reuse programs

* Tracking

* Training

* Hazardous Waste Pad

Management

* Second Tier Development & Mgmt

* Waste Treatment

* Container Prep & Labels

* Safety-Health Studies

* Container Management

* Emergency Response

RESOURCE MANAGEMENT PROGRAM SCOPE OF PROGRAM

LADDER

LEVEL IV

* Disposal

* Hauling

* Consultation

* Limited Cardboard

recovery using MRF

* Limited Off-site support

LEVEL III

* Disposal

* Hauling

* Consultation

LEVEL II

* Disposal

* Hauling

LEVEL I

* Disposal


GEP


Non-Recycled Waste Reductions 2000 –

2Q09

0

100,000

200,000

300,000

400,000

500,000

600,000

700,000

2000 2001 2002 2003 2004 2005 2006 2007 2008 2Q09

Met

ric

To

ns

GMNA

Global

77% Reduction in Non-Recycled Waste since 2000

Global Goal – 15% per vehicle reduction, 2005-20102005-2Q09 – Global: 50% reduction in NR waste; 35% on a per vehicle basis


GEP


Next Step – 2007

Global By-Products Management


GEP


By-Product Former State

Several groups were managing materials with overlapping responsibilities Created confusion for plants, suppliers, others

Material values were not maximized

Resource Managers are on-site in our plants Primary focus is compliance

Secondary focus on waste minimization projects


GEP


Global By-Product Initiative

Background:

In North America, Vice President of Manufacturing in NA and other top leadership embraced this Global By-Products Strategy

Direction:

Fully implement program at all NA assembly plants as quickly as possible

Status:

In 2007 all US and Canada Assembly Implemented, several Stamping

Mexico implemented in 2008

Over $1 Billion in value achieved in 2008


GEP


Absorbents Batteries Cardboard Fluids Foundry wastes Grinding swarf Metal scrap Oil

Plastics Paper Rubber Sludges Solvents Textiles Vehicle parts Wood

By-Products Definition:

“Materials not incorporated into GM Products”


GEP


By-Product Recovery Vision

Use the Resource Managers to achieve zero landfill and recover all resources to their highest value

Batteries

Cardboard

Filters

Fluids

Foundry wastes

Grinding swarf

Oil

Plastics

Paper

RubberSludges

Solvents

Textiles

Trash

Wood

Vehicle Components

Metal Scrap


GEP


Current State – By-Product Flow

Others

Vehicle Parts

Markets SPO, AR

Stamping

Plastics, Other Recycling

GSC

Metallic Scrap

Team

Assembly Plants

Logistic Centers

Powertrain

Suppliers

WFG

Landfill

WM

Energy

Recovery/Incineration


GEP


Vehicle Parts

Markets SPO, AR

Stamping

Plastics, Other Recycling

Metallic Scrap

Team

Assembly Plants

Logistic Centers

Powertrain

Suppliers

WFG

WM

Landfill

Proposed State – By-Product Flow

Energy

Recovery/Incineration


GEP


New State

Expand WM program to manage the disposition of all by-products and become the single point within our facilities

Primary focus is zero landfill and maximum return to GM

Work with existing in-plant personnel

We now place Commodity Resource Managers on-site

Primary focus is waste minimization

Achieve financial value for commodities

Fill all gaps in by-product management commodities


GEP


Vehicle Component Recovery By-Products Strategy Included earmarking minor

dents and scratched components into SPO Outlet Shop on a multi-facility basis to enhance financial value


GEP


By-Product Summary


GEP


Zero Landfill StrategyA Logical Next Step


GEP


GM’s Road to Zero

All by-products that come from ongoing, day-to-day manufacturing-related operations, must be taken into account as part of a landfill-free designation. This includes episodic/ periodic by-products, such as pit cleanouts. To qualify for a "landfill-free" status, facilities must handle by-products by any other method except placement in a landfill.

Zero Landfill


GEP


• 51 GM operations landfill free

• Based on manufacturing outputs (By-Product/waste)

• Many years required to enable this result

• Goal is 50% Landfill Free by 2010

• Executive level & Plant level teams embraced concept

• Green recognized as a strategic business strategy

Zero Landfill Overview


GEP


1

12

27

4451

21

42

54

72

143

0

25

50

75

100

125

150

175

200

2005 2006 2007 2008 2009 2010 Goal

Nu

mb

er

of P

lan

ts

Operations at zero-landfill Targets Total Operations

WFG Technology Innovations

Landfill Free Status

71% toward goal as of 2Q09


GEP


Landfill Free StatusGM North America

(20)GMPT Flint Engine South

GMPT Tonawanda Engine 1 & 5

GMPT Wixom Facilities

GMPT Baltimore Transmission

GMSC Flint Tool & Die

GMSC Marion

GMPT Warren Transmission

GMPT Silao Engine

GMPT Silao Transmission

GMVM Silao Assembly

GMSC Silao

GMPT St. Catharine's Ontario St.

GMPT St. Catharine's Glendale Ave

GMVM Ramos Arizpe Assembly 1

GMVM Ramos Arizpe Assembly 2

GMSC Ramos Arizpe

GMPT Ramos Arizpe Engine

GMPT Ramos Arizpe Transmission

GMPT Toledo Transmission

GM Europe (15)GMSC Kaiserslautern, Germany

GMPT Kaiserslautern, Germany

GMVM Eisenach, Germany

GMPT Strasbourg, France

GMVM Gliwice, Poland

GMSC Gliwice, Poland

GMPT Aspern, Austria

GMPT Bochum, Germany

GMVM Bochum, Germany

GMSC Bochum, Germany

GMPT Russelsheim, Germany

GMPT Szentgotthard, Hungary

GMPT Tychy, Poland

GMVM Antwerp, Belgium

GMSC Antwerp, Belgium

GM Asia-Pacific (16)GMDAT Gunsan, Korea

GMDAT Gunsan, Korea

GMDAT Gunsan, Korea

GMDAT Bupyeong, Korea

GMDAT Bupyeong 1, Korea

GMDAT Bupyeong 2, Korea

GMDAT Bupyeong, Korea

GMDAT Bupyeong Tool & Die

SGM Shanghai

SGM Shanghai

SGM Shanghai North

SGM Shanghai South

GMDAT Changwon, Korea

GMDAT Changwon , Korea

GMDAT Changwon, Korea

GMDAT Changwon Tool & Die

51 Global Operations are landfill free

Assembly (13)Powertrain (24)Stamping (14)


GEP


• E-Metric placed into plant scorecards

• Grinding swarf project of 2004

• Rolled media recycling project in 2005

• Partnership with Purchasing and Finance

• Global Scrap Initiative

Program Enablers


GEP


Rolled Media Recycling Project


GEP


Grinding Swarf Project


GEP


Initiative Enablers, Going Forward

• Global By-Products Initiative

• Vehicle Component Recovery (VCR)

• Single point of contact from “Point of

Accumulation”

• Multi-facility corporate contracts

• “Roadmap to Zero”

• Best Practices, Work Instructions, etc

• By-product to energy options


GEP


Primary Challenges

• Foundry sand

• Plant trash

• Packaging by-product

• Transportation of commodities

• F-019 WWTP Sludge

• Paint sludge


GEP


Goal is to recycle GM plant’s used oil (on-site or off-site) and re-use in the plant for cost savings and reduced environmental footprint

Largest portion of used oil sent off-site to 2 managers:

Base oil reclaimer, used oil re-refiner for formulation into products to sell back to GM

GM (US and Canada) plants use 50% reclaimed or re-refined oil – 3.5M gallons/year (some plants >70% recycled oil use)

Recycled oil purchase savings greater than entire cost of recycling program

Significant focus on on-site efforts for additional savings

GM Used Oil Program


GEP


Design for the Environment (DfE)


GEP


Design for the Environment (DfE)

Our Mission:

Integrate life-cycle environmental considerations into product development, manufacturing process and material selection activities in order to reduce product and facility impacts, minimize costs, as well as promote environmental sustainability.


GEP


Other DfE Initiatives

Sustainability

Closed loop recycling

GM Green Products

Purge Program

Multi-facility Initiatives


GEP


GMR2 Demonstration

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Documents

gm plant

environmental reports

2q09 global goal

development programs

productsmanagement gep

resource management

history resource management

gm manufacturing facility