Green Engineering at General Motors:

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1 Green Engineering at General Motors: Selected Case Studies from Manufacturing, Facility, and Product Design John Bradburn, Sr. Environmental Project Engineer Casey Essary, Environmental Engineer Miguel Antonetti, Environmental Supervisor Jackie Quinn, Sr. Project Engineer, DFE

2 Since 1995, GM has.. Cut total waste/vehicle by 30% Cut non-recycled waste by 76% Boosted recycling to 88% of all waste Cut natural gas use by 25% 3 plants operating with zero landfilled wastes by recycling and generating electricity 2

3 Outline Zero Landfill Manufacturing Processes Grinding Swarf Recycling Solvent Wiper Recycling Filtration Technologies Facility Design Landfill Gas Product Design Examples 3

4 Zero Landfill Manufacturing Processes: Machining Plants GM has 3 plants with Zero Landfill status Flint Engine South (867 people/ 1,650 engines/day) Tonawanda (2,500 people/4,000 engines/day) Wixom (Custom engines, 40/day) >95% of waste recycled, remainder incinerated to generate electricity None of the plants were originally designed to operate this way 4

5 GM Uses Resource Managers to provide inplant resources to help GM achieve zero landfill and recover all resources to their highest value Batteries Sludges Filters Solvents Cardboard Fluids Foundry wastes Plastics Trash Wood Textiles Vehicle Component Recovery Grinding swarf Metal scrap Paper Oil Rubber 5

6 Top 5 Wastes by Tonnage Zero Landfill Plants Scrap metal (almost 30,000 T) General plant trash (1,413 T Energy) Swarf (1,389T) Used oil (855T) Wood (388 T) *FES+TON 6

7 Tonawanda Engine Energy Recovery, 4.4% Recycle/Reuse 7.2% Landfill 0.6% Recycled Plastic 0.2% Incineration 0.01% Recycled Metal 87.7% 7

8 Manufacturing Process WOOD CARDBOARD GLOVES ROUGH MACHINED CASTING CONVENTIONAL MACHINING CHIPS COOLANT SWARF CUTTING TOOLS FILTERS OIL LIGHTBULBS GLOVES BATTERIES PAPER PLASTIC WIPES MEDICAL WASTES SHIPPING LEAK TESTING/ NDE SCRAP PARTS 8

9 Top 5 Wastes by Tonnage Zero Landfill Plants Scrap metal (almost 30,000 T) General plant trash (1,413 T Energy) Swarf (1,389T) Used oil (855T) Wood (388 T) *FES+TON 9

10 Dealing With Swarf What can you do with swarf? Swarf=mix of oil, water, fine metal particles, textiles Mix with chips & sell to steel mills Cutting fluid filter media mixed with grinding swarf made it hard to find a market Adding recycling to existing plants floor space, systems, training Needed a Best Practice to be consistent 10

11 Dealing with Swarf Eliminate roll media contamination Dry it no dripping trucks leaving the plant Compact it easier to reuse Cross functional team makes it happen: Resource manager, environmental engineer, millwright, & the guy who empties the swarf boxes 11

12 Keeping Filter Media Out of Swarf Polymer fabric filters machining coolant Added a rewinder to keep used media out of swarf Specified filters made from a single polymer. Easier to recycle, and can be lower cost than multiple component systems How is it recycled? Shred, mix with polyethylene Made into pallet spacers 3.5M so far 12

13 Clean and Re-use Dry Dust Air Filtration Cartridges Cylindrical air filters collect dust from welding, shot blast, powder coating, and general air makeup systems. GM North America used >40,000/year Bulky in waste stream In 2005, we cleaned and reused > 7,900 filters at >$400,000 savings, > 1,600 Yd 3 landfill elimination ~0.6m 13

14 New Filtration Technology: Easier Cleaning, Longer Life Herding Filtration --PTFE coated rigid sintered PE filter panel Forms micro-porous surface, blocking PM from embedding into the filter elements Coating enhances removal and eliminate adhesion of viscous matter (styrene, creosote) Filter life up to 7 years 1 1. Separated Dust PTFE surface size of pores 2-3 µm thickness of coat approx. 5 µm 3. Rigid filter element PE size of pores approx. 30 µm, wall thickness 4mm 14

15 Rags to Riches: Solvent Wipers Polypropylene solvent rags clean vehicle surfaces in our assembly plants The polypropylene is converted to pellets and used as feedstock for new vehicle parts. 15

16 Facility Design: Landfill Gas Methane: significant greenhouse gas 5 GM plants use landfill generated methane in their steam boilers Landfill gas can supply over half the energy for the boilers and cut costs $500k/yr at a typical plant 16

17 Product Design: Pontiac G6 Hydroformed steel front engine cradle: reduced scrap and saved 354 tons of weld wire for the 2005 model year. Eliminated lead from corrosion protection coating. Ch. Hartl / Journal of Materials Processing Technology 167 (2005)

18 Product Design: Saturn VUE 18

19 Fluids 2007 Saturn VUE Hybrid Long life coolant saves a flush & change Oil life sensor change it when you need to Fill for life transmission fluid Electric Motors Electric Power steering no hydraulic fluid, lighter, +0.9 mpg Regulated voltage control mpg Spark Plug Added platinum to double the life to 100k mi Recycled Content 20% in wheel liners Projecting 20% better mileage than non-hybrid Vue 19

20 Design for Disassembly 20

21 Design for Disassembly Whenever possible choose single material that is easy to recycle; minimize number of fastener sizes. Disassembly manuals are on public website 21

22 Making New Green Engineers 22

23 Summary Find opportunities by analyzing your systems: top 5 wastes, top 5 disposal costs, dumpster diving. Educate your engineers Consortia, EPA Wastewise & State programs can give you ideas. Working with universities can uncover opportunities including fresh eyes of coops & interns. Many green manufacturing and facility initiatives are also cost savings 23

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