United States Environmental Protection Agency Solid Waste and Emergency Response (5306W) EPA 530-F-97-026 August 1997 AEPA i Reduction in VOC and Sludge Emissions . $85K Savings Annually ! Fewer Potential Legal Liabilities This is a perfect example of how waste minimization can often be very simple - it is just a matter of paying atten- tion to details, fine-tuning, and maximizing small opportu- nities for change Waste Minimization: Reducing Paint Waste Through Efficiency General Motors Hamtramck Plant What Does the GM Hamtramck Plant Do? The General Motors Hamtramck plant (Detroit and Hamtramck, Michigan) manufactures and paints various GM automobiles. At the time this project occurred, the Hamtramck facility was responsible for the production of flagship cars in the Cadillac line: the DeVille, Seville, and Eldorado. What Did They Accomplish? Constantly looking for ways to improve product quality and reduce waste, the plant recognized that its primer surfacer application could be improved. In particular, the jets were spraying paint for several frac- tions of a second after the target automobile had moved out of range. By changing the timing, an even coat of paint was applied while waste was slashed. The end result was a reduction of 5.5 tons of volatile organic compounds (VOC) emissions and four tons of paint sludge per year. Environmental Achievements Although the timing of the paint jets was adjusted by mere fractions of a second, the tremendous volume on which the plant operates meant that these simple changes yielded significant results. Adjusting the jets by varying increments resulted in the plant reducing 3,000 gallons of primer waste annually (which contained toluene, xylene, methanol and butyl cellosolve acetate). Regulatory Relief Though the GM Hamtramck plant's regulatory status has not changed, reduced waste makes for fewer opportunities for spills, acci- dents and violations, and therefore fewer potential legal liabilities. The Implementation Process The GM Hamtramck facility reg- ularly holds meetings to examine methods for product improvement, waste reduction, and cost savings. Input comes from environmental engineering, paint shop mainte- nance, paint production, facility engineering, powerhouse personnel, purchasing, and finance. Supplier representatives are also an integral part of the team. Implementation of this project involved no capital or labor costs on the part of GM. Worker training was unnecessary. This is a perfect example of how waste minimization can often be very simple—it is just a ------- Waste Minimization: Reducing Paint Waste Through Efficiency General Motors Hamtramck Plant matter of paying attention to details, fine-tuning, and maximizing small opportunities for change. The effort took about a month, during which time an operational audit was conducted, the data ana- lyzed, and solutions implemented. Tracking of success included gather- ing data on Toxic Release Inventory chemicals and materials consump- tion. The latter was accomplished via a purchasing system that tracks all purchases on a monthly basis. Economics At the time the project was implemented, an annual savings of $85,000 was achieved. This savings is primarily the result of lower paint and waste disposal costs. The sav- ings have varied over time, due to production volume fluctuations. In addition, waste disposal require- ments were cut. Words to the Wise Senior Environmental Engineer Roger Johnson noted that communi- cation of successes is vital for a pol- lution prevention effort. Doing so not only gains recognition, but may also elicit ideas from people who might not otherwise have participat- ed. "If you achieve a success - com- municate it!"- Roger Johnson Another important aspect men- tioned by Mr. Johnson is creating a culture that accepts change and innovation. Doing so facilitates rapid development of new solutions. Hurdles The project was implemented during scheduled plant shutdowns, eliminating any disruptions. Product quality rose, since the cars now receive a more even application of paint. WASTE MINIMIZATION NATIONAL PLAN For more information about the Waste Minimization National Plan, call (800) 424-9346 or check the World Wide Web at http://www.epa.gov/epaoswer/hazwaste/minimize Reducing Tones m Our (ton's Waste ------- |