DENSO Manufacturing U.K. Ltd - Winner of a Green Business Award 2009

 
DENSO aerial view Winners of a Green Business award Cotton wipes DMUK plant Oil waste storage Assembly line Assembly line Pallet storage

DENSO Manufacturing U.K. Ltd - Winner of a Green Business Award 2009

Award scheme

Green Business Awards 2009

Award

Waste Reduction Category award

Name

DENSO Manufacturing U.K. Ltd, Telford

Organisation

DENSO is a leading supplier of advanced automotive technology, systems and components for all the world's major automakers, operates in 32 countries and regions with approximately 120,000 employees.  Veolia, Envirowise, NISP and BESST were key partners.

Summary

From 2004 DENSO established an Environmental Champions group, within the plant, who started looking at reducing raw material use, improving energy conservation, energy reclamation and waste water management.

In 2004, 55 tonnes were going to landfill every month, but within two years they managed to reduce this to zero. As a result of accurate waste classification, DENSO now recycle 94% of all waste produced. The remaining 6% goes for incineration, with some energy recovery, but since 2006 none goes to landfill. Each area of production was challenged to improve their performance and each week it was monitored to determine whether they had made any progress.

Once the zero landfill target had been achieved, the company then moved the focus from waste management to resource management. The implementation of a waste minimisation plan was followed by a resource efficiency programme.

The challenges

  • One of DENSO's Eco-vision 2015 policy targets is to achieve zero landfill in all manufacturing sites worldwide.
  • 2009 waste minimisation targets are a 10% reduction (tons / £M Sales) in both total waste and hazardous waste and a 5% reduction (tons / £M Sales) in non-recyclable waste (General Waste).
  • To reduce the volume of filter cake generated in the effluent treatment plant by 75% and reduce recycling cost by 80%.
  • A further 10% reduction (from last year's figures) in flux powder waste through kaizen groups activity, optimizing processes.
  • To introduce returnable packaging to collect and dispose of hazardous waste for incineration.
  • To be able to segregate waste food and divert it to the anaerobic digester at Harper Adams University.
  • To introduce long lasting gloves and end use of single use gloves.

 

The solutions 

  • Implemented lean manufacturing 5 S's and TPM programmes.
  • Re-work of some rejected parts has seen a significant reduction in production scrap.
  • Improved monitoring of the production scrap per area highlighted the targeted areas.
  • Implemented internal procedures for waste packaging in pallet management and worked in partnership with their suppliers in order to increase returnable packaging and reduce cardboard.
  • Company-wide resource efficiency programme started last year, with training provided to their network of Environmental Champions who are now in charge of producing a waste mapping in all areas and highlighting opportunities for resource efficiency.
  • Replaced paper tissue for cotton wipes that are washable and re-usable, avoiding waste generation.
  • Scheduled the monthly consumption monitoring of some chemicals and consumables to help optimize the usage of materials in manufacturing processes.
  • Raised awareness through a display for customers and visitors in the reception area, permanent contractors (canteen and cleaning staff) were given induction on waste segregation and a very comprehensive awareness programme was set up for their permanent workforce (audits, inspections, posters, campaigns).

 

The results

  • The improvement of some specific processes (flux application and paint powder) has lead to a very significant reduction in hazardous waste.
  • £172,000 annual cost savings through energy efficiency initiatives implemented across the plan.
  • £100,000 cost savings in two years by introducing a pallet re-use and resale scheme.
  • £5,000 reduction in hazardous waste disposal costs identified in the first year by switching from disposable tissues to washable cotton wipes, estimated cost savings of 50% by changing the way lubricating oil is delivered.
  • Achieving zero landfill & implementing a resource efficiency and waste minimisation programme led to waste disposal costs were reduced from £137K in 2005 to £54K in 2008. The true cost of waste, counting both visible and hidden costs was reduced by £131K from 2007 to 2008.
  • Reduced aluminium scrap by 60% (57% against sales) in the last 3 years.
  • Through a pallet management scheme we are currently re-using most of the pallets internally, thus reducing the number of pallets from nearly 1000 tons in 2004 to 232 tons in 2006.
  • Introduction of several initiatives in order to move from disposal to waste avoidance, led to a reduction in hazardous waste of 75% and 56% in total solid waste in the last 5 years.
  • Do not contribute to the methane gas coming from landfill sites.
  • By reducing the amount of waste generated they also reduce transport, emissions from incineration and energy used in waste recycling processes.
  • Model of a green organisation for the local community, that not only seeks to minimise its impact on the environment but also aims to support the local community.

 

Learning points

Applying a variety of waste reduction and re-use techniques to its manufacturing plant has enabled DENSO Manufacturing UK Ltd to realise significant cost and environmental benefits.

"DENSO mission is to contribute to Society through research and development that is in harmony with the environment."

DENSO

SWM comment

DENSO Manufacturing U.K. Ltd is a clear example that minimising the impact a company has on the environment can be rewarded by substantial cost benefits.

Contact

For more information please go to the DENSO website.

 

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