creating value through zero waste … honda's journey to zero waste
TRANSCRIPT
Creating Value through Zero Waste … Honda’s Journey to Zero Waste
Robert Bottom, Green Factory Engineer,
Honda of America Manufacturing, Marysville, OH
Wednesday, March 23, 2016
1 p.m. to 2 p.m.
Biographical Information
Robert M. Bottom Staff Engineer
Honda of America, Mfg. 24000 Honda Parkway Marysville, OH 43040
937-644-6415 [email protected]
Robert Bottom is a staff engineer in Honda of America Mfg.’s Facilities Environmental Department. His responsibilities have included managing and reducing solid waste within Honda’s Green Factory Program. In this role, he worked closely with associates at Honda of America’s two auto plants and engine plant in Ohio and also coordinated these activities with other Honda manufacturing facilities in North America. Bottom joined Honda of America in 1994. Prior to his current responsibilities, he was assigned to the company’s Marysville Motorcycle Plant. In this role, he led Green Factory Program activities, including ISO14001 management and environmental compliance for the paint shop. The Motorcycle paint shop received an Ohio Governor's Pollution Prevention Award in 1998 for the introduction of powdercoat frame painting. Bottom holds a B.S. degree in Mechanical Engineering from GMI Engineering & Management Institute (Kettering University) in Flint, Mich.
• Honda and “Zero Waste”
• Honda of America Manufacturing , Inc. (HAM)
Honda in North America
Honda has steadily expanded its capabilities to create products in N.A., from product concept and design, to full development and production
Research & DevelopmentResearch & Development ManufacturingManufacturing SalesSales
Mobility
Automobiles | Powersports | Power Equipment | Marine | Racing | Robotics Technology | HondaJetAutomobiles | Powersports | Power Equipment | Marine | Racing | Robotics Technology | HondaJet
North American Production FacilitiesOhioHonda of America Mfg., Inc.
• Marysville Auto Plant• East Liberty Auto Plant• Anna Engine Plant
Honda Transmission Mfg. of America, Inc.IndianaHonda Manufacturing of Indiana, LLCAlabamaHonda Manufacturing of Alabama, LLCGeorgiaHonda Precision Parts of Georgia, LLCNorth CarolinaHonda Power Equipment Mfg., Inc.Honda Aircraft Company, LLCHonda Aero, Inc.South CarolinaHonda of South Carolina Mfg., Inc.CanadaHonda of Canada Mfg.
• Plant 1• Plant 2• Engine Plant
MexicoHonda de Mexico S.A. de C.V
• Guadalajara Motorcycle/Parts Plant• Guadalajara Auto Plant• Celaya Auto Plant• Celaya Transmission Plant
OhioHonda of America Mfg., Inc.
• Marysville Auto Plant• East Liberty Auto Plant• Anna Engine Plant
Honda Transmission Mfg. of America, Inc.IndianaHonda Manufacturing of Indiana, LLCAlabamaHonda Manufacturing of Alabama, LLCGeorgiaHonda Precision Parts of Georgia, LLCNorth CarolinaHonda Power Equipment Mfg., Inc.Honda Aircraft Company, LLCHonda Aero, Inc.South CarolinaHonda of South Carolina Mfg., Inc.CanadaHonda of Canada Mfg.
• Plant 1• Plant 2• Engine Plant
MexicoHonda de Mexico S.A. de C.V
• Guadalajara Motorcycle/Parts Plant• Guadalajara Auto Plant• Celaya Auto Plant• Celaya Transmission Plant
Honda of America Mfg., Inc.• Marysville Auto Plant• East Liberty Auto Plant• Anna Engine Plant
> 8,200 acres9.2 million sq. ft. under roof
> 10,000 associates
Location Marysville, Ohio
Started production November 1982
Plant size 4 million sq. ft.
Capital investment $4.6 billion
Employment 4,250 associates
Annual capacity 440,000 vehicles
Products Accord SedanAccord CoupeAcura ILXAcura TLX
Honda of America Mfg., Inc. – Marysville
Accord Sedan Accord Coupe Acura ILX Acura TLX
As of Dec. 31, 2014
Location Anna, Ohio
Started production July 1985
Plant size 2.4 million sq. ft.
Capital investment $2.25 billion
Employment 2,800 associates
Annual capacity 1,180,000 engines
Products 4-Cylinder EnginesV-6 EnginesTurbo EnginesCVT Pulleys
4-Cylinder Engines V-6 Engines CVT Pulleys
Honda of America Mfg., Inc. – Anna Engine Plant
As of Dec. 31, 2014
Turbo Engines
Location East Liberty, Ohio
Started production December 1989
Plant size 2.8 million sq. ft.
Capital investment $1.4 billion
Employment 2,350 associates
Annual capacity 240,000 vehicles
Products CR-VAcura RDX
Honda of America Mfg., Inc. – East Liberty
CR-V Acura RDX
As of Dec. 31, 2014
First to meet Clean Air Act requirements
Best Rated #1 in fuel efficiency
Going Beyond Regulations
Honda Environmental Vision
Realizing the joy and freedom of mobility and a sustainable society
where people can enjoy life
“Green Factory”Environmental Issues
Global Regional Local• Depletion of ozone layer
• Global warming
• Natural resource depletion
• Disappearing rainforests
• Acid rain
• Ocean pollution
• Air quality
• Air quality
• Pollution in lakes, rivers
• Contaminated soil
• Landfill capacity
“…awareness for environmental protection in the world is increasing every year…we will begin, in the area of production, to further increase resource efficiency and reduce wastes and toxic substances to the minimum amount. At Honda, we call this next generation plant “Green Factory…”.
Honda President, 1998
Honda’s Response
NA Waste Management Strategy
Recycle
Reuse
Energy Recovery
Reduce -Eliminate
Waste
ZERO landfill
Landfill Waste
But, this will take time….
1 Manage all by-products in most sustainable manner
2 Eliminate all waste going to landfill
TOTAL COST
Technical challenge
Segregation
Market availability
Commodities – cost down
Cost up
Waste – cost up
IDEAL IMAGE: “Eliminate waste loss created in manufacturing operations”
What do we mean when we say Honda is “Zero Landfill Waste”?
•Less than 1% of total manufacturing waste sent to landfill – including beneficial use for daily cover
•“manufacturing waste” includes materials from office areas/cafeterias/service centers/etc.
•Construction debris from major projects is excluded but scrap metal, concrete and asphalt is recycled when possible (on-site area to store, crush / reuse concrete, asphalt and soil)
Achieving “Zero Landfill”
True Zero Landfill achieved at 10 Honda NA manufacturing plants:
Reuse / Recycle
94%
Energy Recovery
5%
Honda North America manufacturing waste management methods:
Landfill
<1%
HAM “Zero Landfill Waste”
FY01 FY02 FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15
Poun
ds p
er H
AM
Aut
o
HAM Landfill lb/HAM Auto
HAM supports the North American initiative and has
reduced landfill waste by over 95% since FY01
Two key focus areas: Improving energy efficiency
Waste management
Reduction in Greenhouse Gas emissions
Environmental Management
Environmental ManagementCentral element of Honda’s environmental oversight and
management structure – commitment to ISO 14001
• All three Honda of America manufacturing plants have been registered since 1998.
•Associates and contractors have procedures for handling waste & recycled materials.
•Program to ensure timely training for new associates / new responsibilities and refresher
training
Associate and contractor training
Environmental Management
The Suggestion Program provides an avenue for individual Associates to submit ideas to improve different aspects of HAM’s business while assisting in the planning, implementation and documentation of those ideas.
The Associate Recognition Program provides recognition and reward to Associates for performing a singular act, above and beyond their normal job responsibilities, which resulted in a significant benefit or prevented a potentially negative impact to HAM and/or HAM Associates.
The NH Circle Program provides an opportunity for associates to work together as a team to solve problems, implement improvements, and develop valuable skills.
Individual contributor & team-based programs
Environmental Management
Associate InvolvementIn the beginning…..
Waste Management
GENERAL TRASH DUMPSTER
NEW RECYCLING STREAMS
Dumpster Diving = NEW RECYCLING
STREAMS
Waste ManagementWhat do we recycle?
Scrap steel from Stamping is reused
to make engines and ferrous parts
Paper, magazines, batteries from office areas
Rubber gloves
• Scrap glass
• Spent solvents• Spent oils and coolants• Aluminum chips/turnings• Copper weld tips• Fluorescent light bulbs• Used rags, gloves, floor mats• Wood (pallets, crates)• Concrete/asphalt• Used wiring
• Cardboard
Plastic Sheeting
Protective caps of all shapes & sizes
….. and the list goes on!!
Reuse cover list
Reuse cover list ①
Purpose
dustcontaminationprotection(chip/O-ring damage)
dustcontaminationprotection(chip/O-ring damage)
dustcontaminationprotection(chip/O-ring damage)
1900A-RWC-A504RADIATOR ASSMEBLY
dustcontamination
dustcontamination
dustcontamination
dustcontamination
Deliverycondition Parts no. PurposePicture / size
Dustcontaminationprotection(結合座面)
Dustcontaminationprotection(結合座面)
DustcontaminationProtection(chip/O-ring damage)
DustcontaminationProtection(chip/O-ring damage)
Dustcontaminationprotection(結合座面)
80100-TA0-A010CONDENSER ASSY
80320-TA6-A010PIPE ASSY AIRCON
77900-STK-A020REEL ASSY CABLE
77900-TA0-C112REEL ASSY CABLE
77900-TA0-C210REEL ASSY CABLE
80100-TA0-A010CONDENSER ASSY
80320-TA6-A010PIPE ASSY AIRCON
製品保証位置固定
製品保証位置固定
30×16×18
33×18×17
Picture / size Deliverycondition Parts no.
80315-TA5-A010
80315-TK4-A010HOSE CIMP
DISCHARGE
40×24×17
40×24×17
17200-RWC-A000CASE ASSY AIR/C
RDX ENG
ACC-ENG
1900A-R40-A500
80311-TK4-A010HOSE CIMP
,SUCTION
7902A-TA5-2002HVAC CPU SUBASSEMBLY
7902A-STK-A400HVAC SUBASSY
Reduction in dumpster size allows team to take ownership and verify contents promoting accountability.
Visual management
Plant – Styrofoam Recycle
AEP required packing material to build ahead FHEV engine
blocks for build out.‐MAP stored/returned Styrofoam engine base blocks for reuse. AEP returned to MAP for recycling in MAP Styrofoam Densifier. ‐ This activity had no input cost and saved AEP from purchasing temporary packaging material.
Cooperation among plants and within plants
Communication Link
Internal communication within departments
Internal communication – associate magazine
OEPA Encouraging Environmental Excellence “Gold” Level Recognition of all 3 HAM Plants
AEP Team ELP Team MAP Team
www.honda.com/environment
Environmental ReportingIn 2005, Honda published our first North America
Environmental report.
Are there any questions ?
Robert BottomHonda of America, Mfg., Inc.
24000 Honda ParkwayMarysville, OH 43404