freightliner custom chassis corporation’s zero waste to landfill journey

GREEN TEAM

552 Hyatt Street, Gaffney South Carolina 29341

Freightliner Custom Chassis Corporation’s Zero Waste to Landfill

Journey

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THE EVOLUTION OF ENVIRONMENTAL RESPONSIBILITY AT FCCC

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WHO WE AREFreightliner Custom Chassis Corporation (FCCC) was formed in 1995 after Freightliner Corporation (now Daimler) acquired the Chassis Division of Oshkosh Corporation289,000 sq. ft. facility 75 acres offering 227,400 sq. ft. of manufacturing and 33,600 sq. ft. of research, dynamometer and paint processesEmploys approximately 500 team members within its manufacturing, engineering, sales/marketing and finance operations Registered to ISO 9001: 2008 quality standard Registered to ISO 14001: 2004 environmental standard

FCCC manufactures Class 4 - 8 chassis for motorhomes, walk-in vans, commercial buses and school buses

What We Do

FCCC Aerial Photo

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FCCC CUSTOMERS

Walk-in Van:FedEx, UPS, Penske, Ryder, Aramark, Cintas, G&K Services, AmeriPride, LDV, Con Edison, Canpar, Estafeta

Commercial Bus:Caio, Stallion, Glaval, Champion, Supreme, Double K

School Bus:Thomas Built Buses (another DTNA subsidiary)

Motorhome:Winnebago, Coachmen, Tiffin, Forest River, Damon, Four Winds, Newmar, Fleetwood

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AWARDS AND RECOGNITION

The FCCC manufacturing facility served as the pilot plant for the Zero Waste to Landfill project initiated by DTNA. Awards and recognition:

FCCC is a member of the South Carolina Environmental Excellence Program for sustaining a superior environmental management system and received the S.C. Earth Day award in April, 2010.

FCCC is a member of the EPA’s WasteWise Program and awarded the 2010 Gold Achievement in December, 2010 for “Waste Reduction in the Workplace”.

FCCC is a member of the South Carolina Smart Business Recycling Program and was awarded in 2010 for its outstanding waste reduction and recycling efforts.

FCCC won the 2009 Daimler Environmental Leadership Award, presented in Stuttgart, Germany on March 25, 2010.

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AWARDS AND RECOGNITION

The FCCC manufacturing facility served as the pilot plant for the Zero Waste to Landfill project initiated by DTNA. Awards and recognition:

FCCC was featured in Green Manufacturer Magazine for successfully achieving Zero Waste to Landfill status in the 2010 October/November Issue.

FCCC was awarded 2010 Large Business Recycling Award by the South Carolina Department of Commerce in November 2010

http://sccommerce.com/

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MOTIVATION FOR IMPLEMENTATIONDaimler’s philosophy of “Shaping Future Transportation” is the motivation for FCCC to recognize ‘green’ challenges and

opportunities. The selection of FCCC as the pilot facility for Zero Waste to Landfill efforts was the catalyst that not only

changed the company culture, but also influenced the visions of employees, the community, suppliers, and vendors.

Monthly Landfill Waste Totals 2006

228,580214,140

337,320

287,320

316,320 309,900

287,480 284,080

246,160 251,060

219,320

196,560

0

50,000

100,000

150,000

200,000

250,000

300,000

350,000

400,000

Jan-06

Feb-06

Mar-06

Apr-06

May-06

Jun-06

Jul-06 Aug-06

Sep-06

Oct-06

Nov-06

Dec-06

Lbs.

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Zero Waste to Landfill Efforts:2007 Solid Landfill Waste:

- 100.37 pounds per chassis built2008 Solid Landfill Waste:

- 35.57 pounds per chassis built2009 Solid Landfill Waste:

- 8.39 pounds per chassis built 76.4% solid landfill waste reduction in 2009 vs. 200896.5% solid landfill waste-free in 2009

Recycling scrap metal Recycling plastic at

satellite facilityCommunity Partnerships

Returnable Packaging

Recycling Containers on Production Line

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Achieved results and benefits of the implementation:

• Through improved awareness and the successful implementation of waste reduction, returnable packaging and recycling at FCCC, solid landfill waste disposal has been eliminated. This improvement has also reduced overall disposal cost by over 60% per EQU.

• FCCC’s recycling rate has increased from 74.8% in January 2008 to it’s current rate of over 98%.

• Solid waste to landfill has declined from 150,000 lbs. monthly in January 2008 to a less than 10,000 lbs. monthly average through 2009. In October 2009, we achieved Zero.

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Solid Waste to Landfill Totals

0

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

MONTHS

LBS

.

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2007 Waste/Recycle Totals Weight Cost RebateTOTAL 8,188,958 $137,006.55 $77,243.23ACTUAL TOTAL COST $59,763.32

Waste Totals 2,274,710Recycling Totals 5,914,248TOTAL (lbs) 8,188,958% Landfill Waste Free 72.2%% Recycling Rate 72.2%

Financial Impact of WasteReduction/Recycling

2008 Waste/Recycle Totals Weight Cost RebateTOTAL (lbs) 4,661,947 $86,349.97 $73,604.21ACTUAL TOTAL COST $12,745.76

Waste Totals 583,340Recycling Totals 4,078,607TOTAL (lbs) 4,661,947% Landfill Waste Free 87.5%% Recycling Rate 87.5%


Waste Totals 97,100Recycling Totals 2,645,934TOTAL (lbs) 2,743,034% Landfill Waste Free 96.5%% Recycling Rate 94.8%

2010 Waste/Rec Totals (ytd - 9/30) Weight Cost RebateTOTAL (lbs) 2,588,491 $6,808.65 $29,749.54ACTUAL TOTAL COST $22,940.89

Waste Totals 0Recycling Totals 2,588,491TOTAL (lbs) 2,588,491% Landfill Waste Free 100.0%% Recycling Rate 97.6%


Waste Totals 0Recycling Totals 3,123,058TOTAL (lbs) 3,123,058% Landfill Waste Free 100.0%% Recycling Rate 98.0%

2006 2007 2008 2009 2010 20110.0%

20.0%

40.0%

60.0%

80.0%

100.0%

FCCC Recycling Rate

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Our Journey to ZWTL

62.3% reduction in waste to landfill/EQU

versus 2007 baseline. FCCC

selected as DTNA pilot facility for

Zero Waste Initiative.

Founded FCCC “Green Team” and Launched

FCCC Env. Webpage on

FCCC Online.

Registered for EPA WasteWise

partnership.

Recognized by EPA WasteWise for 2007 waste

reductions.42% reduction in waste to landfill/EQU versus same

time in 2007.

Began use of recycling centers in canteen areas.

Finalized details with contractors

for remaining waste stream

recycling.

Plastics/Rubber recycling programs

implemented.

58% reduction in waste to landfill/EQU versus

same time in 2007.94.1% solid waste

landfill free for September.

Oct2009

Jan - Sept 2009

Dec2008

Nov2008

Oct2008

Sept2008

Aug2008

July2008

June2008

May2008

April2008

Mar2008

Feb2008

Jan2008

Dec2007

Nov2007

Oct2007

Sept2007

Visited Subaru (Indiana) to

review waste reduction program.

Accepted as partner to EPA

WasteWise program.

Facility-wide implementation of

current comprehensive

recycling programs.

Cherokee County Recycling granted FCCC an on-site roll-off.

FCCC awarded 2008 Employer Contract of the Year by

SC Vocational Rehabilitation for recycling efforts and jobs produced.

Goal of zero waste to landfill for FCCC facility

(Jan 2010).

FCCC recognized as members of SCEEP

and SC Smart Business Program

FCCC awarded by South Carolina Smart Business

Recycling for 2009

FCCC partnership with Gaffney High School to promote

waste reduction

FCCC achieves 97.3% landfill waste free

status for the month of July

FCCC reaches Zero Waste to

Landfill

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FCCC, like many other industries, filled local landfill sites with tons of solid municipal waste from our production processes. All waste generated was collected in single source containers then dumped. Easily accessible items such as cardboard and wood pallets were then pulled out and recycled.

Traditional Practices

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December/January 2008 – A volunteer group of cross-functional employees gathered to develop a strategic plan for accomplishing Zero Waste to Landfill. The FCCC Green Team was formed.

FCCC Green Team

Freightliner Custom Chassis’ Green Team commits to providing a cleaner and healthier environment by reducing our overall footprint within our community. We will do this by continuously improving in our environmental awareness and processes.

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January 2008 – One of the first questions from the Green Team was, “How will we get this information that is discussed here out to everyone?”

Communication

FCCC Green Team SharePoint

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February 2008 – You can’t eliminate something if you do not know that it exist.

What do we already do?

GO & SEE

DUMPSTER DIVE

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February 2008 – What was in our trash cans? Teams 401/402 was selected to be a pilot area within FCCC because of the variety of trash found during our dumpster dive.

What do we already do?

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February/March 2008 – Standardized identification was needed to easily identify recycling opportunities

Lets Get Started!

Standardization Chart

42% WTL reduction

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March 2008 – Implementation in Canteen and Break Areas

Lets Get Started!

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2008 – Corporate Returnable Packaging; Reduction of waste in restrooms

Other Reduction Opportunities

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April 2008 – Benchmark and BORROW PROUDLY! We borrowed from “The Best”.

Borrow Proudly

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Sorting at Point of Use

May-August 2008 – Having seen that it can be done, we realized that what we were doing just might work. We decided to maintain our current path toward ZWTL. We needed to sort recyclables at the point of use.

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May-August 2008 – Plastics are collected in easily recognized color containers from point of use to centralized collection locations.

58% WTL reduction

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May-August 2008 – Plastics are sent to South Carolina Vocational Rehabilitation for further segregation to increase our recycling rebates.

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Partnerships Made

October 2008 – A Cherokee County Recycling Center and FCCC partnership developed with the collection of PET drink bottles, mixed paper and front office cardboard. This donation of recyclables helps fund recycling in the county.

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Benefits of Recycling

2008 – Scrap rubber hoses is recycled to manufacture playground mulch and other products, all made from 100% recycled rubber.

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Spread the Culture

2009 - Present – Partnerships and mentor programs developed along the journey to ZWTL. These partnerships have fostered awareness and education toward a sustainable future for our community.

FCCC

CustomerCom

Supplier Supplier

CommunityCustomer

FCCC

http://www.cherokee1.k12.sc.us/ghs/images/Bricks%20R%20Us/Warpath%20PDF.pdf

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End in Sight

October 2009 – A newly developed partnership with VLS Recovery provided our last need to remove the “leftovers” from the landfill.

General non-recyclable waste sent to LAST landfill transfer site drop. This load consisted of 5 weeks of non-recyclable waste.

Poor attention to detail allowed recyclables to end up in local landfills. Compactor emptied 1-2 times daily at transfer site.

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Celebrate Success!!!

October 2009 – FCCC celebrated the success of achieving ZERO Waste to Landfill!!!!

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Covering Sustainability

February 2009 – The need for Continuous Improvement and Sustainability of our Environmental Management System depended on the employees understanding their individual impacts to the environment.

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2009 – New employee orientation training includes Aspect/Impact training and recycling standards. Recycling has become a standardized ISO 14001 procedure with annual refresher training for all FCCC employees.

Environmental Impacts

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2009 - Present – Six Sigma Methodology and LEAN business practices help recognize and eliminate waste, such as paper usage in production and excess nylon hose scrap.

12

SIX SIGMA GREEN BELT PROJECTPROBLEM: Discrepancies on the PPAF and in the paperwork preventing the delivery of the vehicle. This includes PPAF signed incorrectly, PPAF not signed at all, TL reviews, Key Process reviews.

SOLUTION: Working with Jay Lucas and Matt Reed to create an electronic PPAF which will eventually eliminate the need for the paper PPAF.

GREEN TEAM BENEFITS based on 16,000 chassis per year.

Cost Savings

$2,000.00

Folders Custom folders we currently use cost FCCC $.65/folder. 16,000 trucks in 2008. $10,400.00

ITEM Explanation of Cost

Stamps We currently have 400 shop floor employees who are required to use a stamp or PPAF sign off. Cost/stamp is $5.

Paper Average paper in each folder is 25 sheets. 16,000 trucks in 2008. $1,920.00

Print Cartridges Based on calculations provided by Bill Harris, cartridges consumed to print PPAF's for 16,000 trucks is 14. $4,714.29

OTHER BENEFITS:Forces the PPAF to be correct in station (FCCC spends approx 42 hrs/week chasing PPAF discrepancies (Annual Cost $98,280). The storage cost at Iron Mountain would be eliminated or reduced.

Banker Boxes 150 folders/box. 12 boxes cost $80. $720.00

TOTAL: $19,754.29

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THANK YOU“FCCC has come a long way. You used to see very little attempts in recycling, but now employees are more aware not only at work but also at home.” Brian Cody (Assembler)

“Being an RV owner traveling to many campgrounds, it helps secure my happiness in the Freightliner brand to see the elevated awareness that they, as a manufacturer, have in protecting our environment.” Debbie & Ed Drabic, FCCC RV Owner, Maryland

freightliner custom chassis corporation’s zero waste to landfill journey

Documents

gaffney south carolina

selection of fccc

fccc manufacturing facility

landfill efforts

landfill project

green challenges

fccc customers walkin

landfill status