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EMC CORPORATION – APEX, NC2016 MANUFACTURERS ZERO WASTE CONFERENCE
JANE WOODALL, MAY 23, 2016
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Sales Services Solutions SupportPartnerEcosystem
Who We Are:
Our Value to
Customers:
We help customers avoid the risks and reduce the costs associated with managing information, while fully exploiting its value for competitive advantage
EMC is a global company that provides solutions to help our customers store, manage, protect, and analyze their information
How We Deliver
Value:
ABOUT EMC
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EMC’S NORTH CAROLINA PRESENCE
Apex
Manufacturing
4© Copyright 2016 EMC Corporation. All rights reserved.
EMC’S NORTH CAROLINA PRESENCE
Apex
Manufacturing
Plant opened in 1981
388,000 ft2 on 140 acres
– 307,000 ft2 of manufacturing floor space
– 81,000 ft2 of engineering lab space and offices
Lean Six Sigma manufacturing
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EMC’S NORTH CAROLINA PRESENCE
Apex
Manufacturing
Integration and Test
– Atmos
– Avamar
– Centera
– ECS Nile
– DLM
– DCA
– VNX, VNXe
– Data Domain
– Recover Point
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ELECTRONICS = LOTS OF FOAM
• Expanded Polypropylene and Polyethylene
• Recyclable – just not economically feasible in its expanded form
• We have LOTS of it
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20152014201320122011
EMC APEX ZWTL TIMELINE
• Corrugated • Office Paper• Pallets
• Film • E-waste
20102009200820072006
• All Paper• Bottles/Cans
• Compost• Foam • Misc Plastic • Small Metal
ZWTL Goal
• PackagingReuse
• WTE
11© Copyright 2016 EMC Corporation. All rights reserved.
APEX WASTE STREAM ANALYSIS
2015 Total Apex Manufacturing Waste Stream – 4035.5 Tons
Recycle
82.21%
RMR
Bott
les &
Cans
Corr
ugate
d
Densifie
dFoam
Film
Meta
l
Pla
stics
Pallets
Iron Mtn
Paper
Avnet
Ew
aste
Reuse
15.74%
Atlas & Rand
Pallets
Corr
ugate
d
Avnet
Ew
aste
Waste To
Energy
1.64%
Republic
Cafe
teria,
Restr
oom
&
Non-
Recycla
ble
Tra
sh
Compost
0.36%
Brooks
Cafe
teria
Univ & Haz
0.02%
Ecoflow
Sold
er
&
Flu
ore
scent
Lam
ps
Landfill
0.04%
RMR
Mis
cTra
sh
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REDUCE: APEX PAPER USAGE (IMAGES PRINTED)
4665
2987
2624
3088 32813527
3159
2338
2624
32.5
25.2
21.4
20.3 18.9
19.520.7
20.3
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
2008 2009 2010 2011 2012 2013 2014 2015 2016Target
Ima
ge
s p
er
Unit
Ima
ge
s P
rin
ted
(k)
Images Printed Images Printed per Unit
Lean Six Sigma Green Belt Project
Lean Six Sigma Black Belt Project
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• Oracle Paper Reduction Black Belt Project 6S02220– Reduced printing by 706k sheets per year
– $93k in annual savings (printing, storage, and labor costs)
• Printer default settings changed to duplex
• Communication and awareness through metrics
• Green Belt Project 6S03866 (after ERP system change to SAP)– Reduced printing by 510K sheets per year
– $19.4K reduction in printing costs per year
APEX PAPER USAGE REDUCTION(IMAGES PRINTED)
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REDUCING SCRAP, PACKAGING, PAPER TAGS
• Cabinet Side Skin & Trim In-Process Scrap Reduction Green Belt Project 6S02073– 83% reduction in trim panel scrap
– 44% reduction in side skin scrap
– $30k per year in hard savings
• Clariion Cabinet Ramp Reduction Lean Kaizen LK00616– Eliminated 2692 plywood ramps per year
– $111k per year in hard savings
• Cable Bundling Lean “Just Do It” Project– Eliminates separate packaging for cables by tying cable bundles inside cabinets
– $4k per year in labor and material savings
• Electronic Failure Tag Black Belt Project 6S01892– Eliminated printing of 492k paper tags per year
– $69k in annual savings (materials, labor costs)
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REUSE: PARKING LOT RENOVATION
• Completed during the summer of 2008
• 100% of materials reused on site
– 2700 cubic yards of asphalt (used as base for new paving)
– 3908 cubic yards of soil
• Reclaimed 2.6 acres of “green” space
• Added employee walking path
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REUSE: PACKAGING INITIATIVES
• Reverse Logistics Packaging Reuse Lean “Just Do It” Project
– Reuses good packaging from field returns
– $678k in material savings for 2009
• Cabinet Packaging Reuse Green Belt Project 6S01690
– Implemented a return process for cabinet brackets
– Saves approximately 22k metal brackets per year from going to landfill
– $250k per year in hard savings
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ZERO LANDFILL(REDUCE, REUSE, RECYCLE)
335
203.1
175.4
133.7
72.4
1.5
235
168
101
68
3417
0.0027
0.0013
0.001
0.0007
0.0005
0.0000
0.0005
0.0010
0.0015
0.0020
0.0025
0.0030
0
50
100
150
200
250
300
350
400
2010 2011 2012 2013 2014 2015 2016
To
ns P
er
Un
it
So
lid W
aste
(to
ns)
Tipping Weights Target Tons Per Unit
96.8%
98.3%Diverted
99.96%Diverted
Lean Six Sigma Green Belt Project &
Packaging Reuse
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EMC APEX WASTE STREAM
Recycle79.6%
Reuse0.4%
WTE4%
Haz & Univ0.04%
Landfill15.97%
Recycle82.2%
Reuse15.74%
WTE1.64%
Compost0.36%
Landfill0.04%
Haz & Univ0.02%
2010 2015