John Bradburn and David Randall General Motors
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John Bradburn and David Randall
General Motors
Enablers of Green Projects
Manufacturing
Community
Supplier Partnership for the
Environment Projects
Manufacturing Process
General Motors is not a chemical
company
But highly dependent on chemicals for
manufacturing including paints,
coatings, sealers, coolants, etc.
So how do we evaluate new chemicals?
1% ground sea shells
So how do we compare potential new
chemicals and chemistries, as well as
encourage research in areas we are
interested in?
Develop of formalized innovation process and talk to
your suppliers about their innovations.
Create a process to review innovations, a method to
rank them, and a way to bring them into
development.
Environment
VOCs
Waste
Water
Odor
GHGs
Energy
Example: Orion Assembly
Orion Assembly is
located in Orion
Township, MI
Originally opened in
1983
Paint Shop
Reconstructed in 2010
Goals
Reduce energy intensity
Reduce capital cost
Required reviewing all potential methods for
coating vehicles and reviewing innovations
that our suppliers had proposed.
Used two newer chemistries that were
innovations from our suppliers:
à Pretreatment
à Integrated Process Vehicle Painting
Innovation: Looking for a lower
energy intensity pretreatment
Pretreatment is the first process
in the paint shop.
In this process, the vehicle body is cleaned
and prepared to receive paint.
In the past, this was done with using a Zinc
Phosphate process
Based on a supplier innovation, GM is using
a new Thin Film Pretreatment System.
So how does Thin film save energy?
Typical GM Phosphate Pretreatment System
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Multi Cleaner Water Phosphate Water Water DI Water
Conditioner Passivation Rinses
Stages Rinses Rinse Rinse
Typical Thin Film Pretreatment Protocol
(1) (2) (3) (4) (5) (6) (7) (8)
Multi Cleaner Water Rinses Thin Film Water DI Water
Stages Pretreatment Rinse Rinse
Reduction in capital costs (eight tanks
instead of ten)
Reduction in energy costs
(baths are not required to
be heated)
Reduction in water usage
Reduction in metals found in sludge
(eliminates Ni and Mn, reduction in Zn)
Eliminates need for chemical boilouts Innovation: Being able
to apply a second layer
of paint without going
through an oven.
Traditionally a prime coat of paint is
applied and then baked in an oven.
Then the basecoat (color) and a clearcoat
are applied.
With the Integrated Process, all three coats
are applied wet and then baked out.Topcoat
Topcoat Quality
Basecoat
Basecoat Clearcoat
Clearcoat OVEN
OVEN Inspection
Inspection&& Verification Post Paint
Finesse Operations
Finesse
To General
Assembly
Prime
Prime Primer Sealing
Sealing&&
Inspection
Inspection&
& OVEN
OVEN Primer Sound
Sound
Moist Surfacer
Surfacer
MoistSand
Sand Damper
Damper
From Body Shop
ELPO
ELPO
Pretreatment
Pretreatment ELPO
ELPO OVEN
OVEN Inspection
Inspection&
&
Sanding
SandingIntegrated
Integrated Process
Process
Topcoat Quality
Verification Post Paint
Primer Basecoat Clearcoat OVEN Inspection &
Operations
Finesse
To General
Assembly
OVEN
Sealing & ELPO
ELPO
Sound Inspection
Inspection &
& OVEN ELPO
ELPO Pretreatment
Pretreatment
Damper Sanding
Sanding
From Body Shop• Reduction in Natural Gas required by removing large Primer Oven and replacing with shorter Sealer Oven • Reduction in Floor Space Required by the removal of inspection zone and Moist Sand Operation
Through a formalized process of
innovations:
Reduces footprint of paint shop by 10%
Uses 50% less energy to produce a vehicle
Reduction in Greenhouse Gas Emissions
Reduction in wastewater treatment sludgeCommunity
Majority of the people in this room
are Green Leaders
How do we expand it from a small
group of strong leaders to part of the
collective consciousness?
I believe we have to move from
being Green Leaders to Green
Mentors. So how do I define Green Leaders and Green
Mentors?
Green Leaders are people striving to reduce the
impact of their products and process on the
environment
Green Mentors are using education and
teaching to get the population to reduce their
impact on the environment.
So how do we enable this change?
Through real world experiences and providing
opportunities that change peoples’ thinking. Example: Senior Design Project at Wayne State
University (CE 4995)
The class is composed of civil engineering students
focused on structural, transportation, water
resources, construction management and
environmental.
For the CE 4995 Senior Design Project, it typically
involves designing a basic building from scratch.
Changed the project to updating Detroit
Hamtramck Assembly Plant City of Detroit bills the Detroit Hamtramck
Assembly Plant monthly based on percent
impervious materials to the following
schedule:
à 10-24% - Billed at $57.71/acre
à 25-49% - Billed at $125.61/acre
à 50-74% - Billed at $210.49/acre
à 75-100% - Billed at $297.06/acre
So GM asked Wayne State students to develop a
plan to reduce impervious material and
stormwater runoffInstall traffic circles
Install traffic in dock areas to
circles in dock improve flow and
areas to improve reduce concrete
flow and reduce
concrete Develop
“Green Roof”
for Visitor
Lobby
Remove parking
lot to reduce
impervious
surfaces
Remove parking lot
to reduce impervious
surfaces.
Install rainwater
harvesting system
from detention ponds Future structural engineers doing green roofs
Future transportation engineers thinking about
less concrete and more efficient trucking routes
Future water resource engineers thinking about
reusing water, instead of just funneling it away
Future construction managers developing costs
for green projects.
And of course, future environmental engineers
actually diving into regulations and ordinances By getting students and young people real world
experience in designing green projects, it could
change their outlooks for the rest of their lives.
That impact of those 20 engineers will last much
longer than my impact at one company.
Expanding and continuing these type of projects
can have a real long term benefit on society.Vision:
Association of automobile OEMs and their suppliers working in
collaboration with the US EPA and other governmental entities to
identify and implement creative projects and programs that will advance
environmental sustainability while providing economic value to the
automotive supply chain.
Mission:
SP provides a forum for small, mid-sized and large automotive and vehicle
suppliers to work with automobile OEMs to learn from each other and
share environmental best practices while also providing economic value
throughout the supply chain.
Work Groups: For More Information:
Steve Hellem, Executive Director, shellem@navista.net
Chemical Issues Kellen Mahoney, Program Manager, kmahoney@navista.net
Energy & Water Phone: 202-530-0096
Materials Efficiency www.supplierspartnership.org
Technology & Networking
www.supplierspartno Surpassed goal to make half of 146
manufacturing sites landfill-free by 2010
o Executives & plant embraced concept;
recognized as strategic business
o Focus on decreasing waste generated, then
recycling unavoidable waste.
o On average, 97% of waste is recycled/reused
and less than 3% is converted to energy at
waste-to-energy facilities, replacing fossil fuelsIn addition to the 78 landfill free Manufacturing Operations, there are 14 Non-Manufacturing Operations that are landfill free
• Converted Asian/U.S cardboard & recycled textile fibers into non-woven substrate for acoustics. • Eliminates plant waste, turns it into vehicle parts. • Substrate contains 25-75% cardboard. • Meets technical, commercial, & economic targets.
Purge Solvent Recycling Gage Products, Livonia, MI, is receiving vehicle paint system purge solvent from all GM US assembly plants, recycling the material at their facility and returning it to GM for reuse in the same applications
Convert scrap battery covers into wood duck nesting boxes, placed on GM grounds to improve habitats. Provides safe place to lay eggs. Example of finding alternative use for product GM receives every day.
GM
Installs Parts in
Chevrolet Volt
GDC Inc.
Produces Volt
Mobile Fluid Components
Recovery
Extracts Oil and
Heritage
Wastewater
Environmental
Collects Booms
Boom
Manufacturer GDC Inc.
Trim Scrap is Sent Produces
to be stuffed into Sonozorb™
Absorbent Booms Acoustical Material
and Parts for GM• ENDURAPRENE™ =
COMPOUND CONTAINS 98% RECYCLED
25% GULF BOOM, CONTENT AIR
PACKAGING AIDS (PE), BAFFLES
TIRE CRUMB (SBR) • BAFFLES DEFLECT
MEETS MTL. WARM AIR FROM
SPECIFICATION GMN-10031 ENGINE AWAY FROM
RADIATOR INTAKEResults And Benefits:
Prevented 227 miles of boom from entering landfills
Prevented 29,000 gallons of oil/water from entering landfills
212,500 pounds of waste eliminated
Eliminated 149 tons of CO2 equivalent emissions
“How wonderful it is that nobody need wait a single
Enabled Implementation by moment before starting to improve the world”
Empowering key stakeholders – Anne Frank
Demonstrated technologies and
processes that provide superior oil
absorbent materials that can be
reused and recycled at end of life
preventing landfill
Formed process for future response
efforts, material selections and
product development strategiesYou can also read
