Creating Value through Zero Waste … Honda's Journey to Zero Waste

Creating Value through Zero Waste … Honda’s Journey to Zero Waste

Robert Bottom, Green Factory Engineer,

Honda of America Manufacturing, Marysville, OH

Wednesday, March 23, 2016

1 p.m. to 2 p.m.

Biographical Information

Robert M. Bottom Staff Engineer

Honda of America, Mfg. 24000 Honda Parkway Marysville, OH 43040

937-644-6415 robert_bottom@ham.honda.com

Robert Bottom is a staff engineer in Honda of America Mfg.’s Facilities Environmental Department. His responsibilities have included managing and reducing solid waste within Honda’s Green Factory Program. In this role, he worked closely with associates at Honda of America’s two auto plants and engine plant in Ohio and also coordinated these activities with other Honda manufacturing facilities in North America. Bottom joined Honda of America in 1994. Prior to his current responsibilities, he was assigned to the company’s Marysville Motorcycle Plant. In this role, he led Green Factory Program activities, including ISO14001 management and environmental compliance for the paint shop. The Motorcycle paint shop received an Ohio Governor's Pollution Prevention Award in 1998 for the introduction of powdercoat frame painting. Bottom holds a B.S. degree in Mechanical Engineering from GMI Engineering & Management Institute (Kettering University) in Flint, Mich.

• Honda and “Zero Waste”

• Honda of America Manufacturing , Inc. (HAM)

Honda in North America

Honda has steadily expanded its capabilities to create products in N.A., from product concept and design, to full development and production

Research & DevelopmentResearch & Development ManufacturingManufacturing SalesSales

Mobility

Automobiles | Powersports | Power Equipment | Marine | Racing | Robotics Technology | HondaJetAutomobiles | Powersports | Power Equipment | Marine | Racing | Robotics Technology | HondaJet

North American Production FacilitiesOhioHonda of America Mfg., Inc.

• Marysville Auto Plant• East Liberty Auto Plant• Anna Engine Plant

Honda Transmission Mfg. of America, Inc.IndianaHonda Manufacturing of Indiana, LLCAlabamaHonda Manufacturing of Alabama, LLCGeorgiaHonda Precision Parts of Georgia, LLCNorth CarolinaHonda Power Equipment Mfg., Inc.Honda Aircraft Company, LLCHonda Aero, Inc.South CarolinaHonda of South Carolina Mfg., Inc.CanadaHonda of Canada Mfg.

• Plant 1• Plant 2• Engine Plant

MexicoHonda de Mexico S.A. de C.V

• Guadalajara Motorcycle/Parts Plant• Guadalajara Auto Plant• Celaya Auto Plant• Celaya Transmission Plant

OhioHonda of America Mfg., Inc.

• Marysville Auto Plant• East Liberty Auto Plant• Anna Engine Plant

Honda Transmission Mfg. of America, Inc.IndianaHonda Manufacturing of Indiana, LLCAlabamaHonda Manufacturing of Alabama, LLCGeorgiaHonda Precision Parts of Georgia, LLCNorth CarolinaHonda Power Equipment Mfg., Inc.Honda Aircraft Company, LLCHonda Aero, Inc.South CarolinaHonda of South Carolina Mfg., Inc.CanadaHonda of Canada Mfg.

• Plant 1• Plant 2• Engine Plant

MexicoHonda de Mexico S.A. de C.V

• Guadalajara Motorcycle/Parts Plant• Guadalajara Auto Plant• Celaya Auto Plant• Celaya Transmission Plant

Honda of America Mfg., Inc.• Marysville Auto Plant• East Liberty Auto Plant• Anna Engine Plant

> 8,200 acres9.2 million sq. ft. under roof

> 10,000 associates

Location Marysville, Ohio

Started production November 1982

Plant size 4 million sq. ft.

Capital investment $4.6 billion

Employment 4,250 associates

Annual capacity 440,000 vehicles

Products Accord SedanAccord CoupeAcura ILXAcura TLX

Honda of America Mfg., Inc. – Marysville

Accord Sedan Accord Coupe Acura ILX Acura TLX

As of Dec. 31, 2014

Location Anna, Ohio

Started production July 1985

Plant size 2.4 million sq. ft.

Capital investment $2.25 billion

Employment 2,800 associates

Annual capacity 1,180,000 engines

Products 4-Cylinder EnginesV-6 EnginesTurbo EnginesCVT Pulleys

4-Cylinder Engines V-6 Engines CVT Pulleys

Honda of America Mfg., Inc. – Anna Engine Plant

As of Dec. 31, 2014

Turbo Engines

Location East Liberty, Ohio

Started production December 1989

Plant size 2.8 million sq. ft.

Capital investment $1.4 billion

Employment 2,350 associates

Annual capacity 240,000 vehicles

Products CR-VAcura RDX

Honda of America Mfg., Inc. – East Liberty

CR-V Acura RDX

As of Dec. 31, 2014

First to meet Clean Air Act requirements

Best Rated #1 in fuel efficiency

Going Beyond Regulations

Honda Environmental Vision

Realizing the joy and freedom of mobility and a sustainable society

where people can enjoy life

“Green Factory”Environmental Issues

Global Regional Local• Depletion of ozone layer

• Global warming

• Natural resource depletion

• Disappearing rainforests

• Acid rain

• Ocean pollution

• Air quality

• Air quality

• Pollution in lakes, rivers

• Contaminated soil

• Landfill capacity

“…awareness for environmental protection in the world is increasing every year…we will begin, in the area of production, to further increase resource efficiency and reduce wastes and toxic substances to the minimum amount. At Honda, we call this next generation plant “Green Factory…”.

Honda President, 1998

Honda’s Response

NA Waste Management Strategy

Recycle

Reuse

Energy Recovery

Reduce -Eliminate

Waste

ZERO landfill

Landfill Waste

But, this will take time….

1 Manage all by-products in most sustainable manner

2 Eliminate all waste going to landfill

TOTAL COST

Technical challenge

Segregation

Market availability

Commodities – cost down

Cost up

Waste – cost up

IDEAL IMAGE: “Eliminate waste loss created in manufacturing operations”

What do we mean when we say Honda is “Zero Landfill Waste”?

•Less than 1% of total manufacturing waste sent to landfill – including beneficial use for daily cover

•“manufacturing waste” includes materials from office areas/cafeterias/service centers/etc.

•Construction debris from major projects is excluded but scrap metal, concrete and asphalt is recycled when possible (on-site area to store, crush / reuse concrete, asphalt and soil)

Achieving “Zero Landfill”

True Zero Landfill achieved at 10 Honda NA manufacturing plants:

Reuse / Recycle

94%

Energy Recovery

5%

Honda North America manufacturing waste management methods:

Landfill

<1%

HAM “Zero Landfill Waste”

FY01 FY02 FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15

Poun

ds p

er H

AM

Aut

o

HAM Landfill lb/HAM Auto

HAM supports the North American initiative and has

reduced landfill waste by over 95% since FY01

Two key focus areas: Improving energy efficiency

Waste management

Reduction in Greenhouse Gas emissions

Environmental Management

Environmental ManagementCentral element of Honda’s environmental oversight and

management structure – commitment to ISO 14001

• All three Honda of America manufacturing plants have been registered since 1998.

•Associates and contractors have procedures for handling waste & recycled materials.

•Program to ensure timely training for new associates / new responsibilities and refresher

training

Associate and contractor training

Environmental Management

The Suggestion Program provides an avenue for individual Associates to submit ideas to improve different aspects of HAM’s business while assisting in the planning, implementation and documentation of those ideas.

The Associate Recognition Program provides recognition and reward to Associates for performing a singular act, above and beyond their normal job responsibilities, which resulted in a significant benefit or prevented a potentially negative impact to HAM and/or HAM Associates.

The NH Circle Program provides an opportunity for associates to work together as a team to solve problems, implement improvements, and develop valuable skills.

Individual contributor & team-based programs

Environmental Management

Associate InvolvementIn the beginning…..

Waste Management

GENERAL TRASH DUMPSTER

NEW RECYCLING STREAMS

Dumpster Diving = NEW RECYCLING

STREAMS

Waste ManagementWhat do we recycle?

Scrap steel from Stamping is reused

to make engines and ferrous parts

Paper, magazines, batteries from office areas

Rubber gloves

• Scrap glass

• Spent solvents• Spent oils and coolants• Aluminum chips/turnings• Copper weld tips• Fluorescent light bulbs• Used rags, gloves, floor mats• Wood (pallets, crates)• Concrete/asphalt• Used wiring

• Cardboard

Plastic Sheeting

Protective caps of all shapes & sizes

….. and the list goes on!!

Reuse cover list

Reuse cover list ①

Purpose

dustcontaminationprotection(chip/O-ring damage)

dustcontaminationprotection(chip/O-ring damage)

dustcontaminationprotection(chip/O-ring damage)

1900A-RWC-A504RADIATOR ASSMEBLY

dustcontamination

dustcontamination

dustcontamination

dustcontamination

Deliverycondition Parts no. PurposePicture / size

Dustcontaminationprotection（結合座面）

Dustcontaminationprotection（結合座面）

DustcontaminationProtection(chip/O-ring damage)

DustcontaminationProtection(chip/O-ring damage)

Dustcontaminationprotection（結合座面）

80100-TA0-A010CONDENSER ASSY

80320-TA6-A010PIPE ASSY AIRCON

77900-STK-A020REEL ASSY CABLE

77900-TA0-C112REEL ASSY CABLE

77900-TA0-C210REEL ASSY CABLE

80100-TA0-A010CONDENSER ASSY

80320-TA6-A010PIPE ASSY AIRCON

製品保証位置固定

製品保証位置固定

30×16×18

33×18×17

Picture / size Deliverycondition Parts no.

80315-TA5-A010

80315-TK4-A010HOSE CIMP

DISCHARGE

40×24×17

40×24×17

17200-RWC-A000CASE ASSY AIR/C

RDX ENG

ACC-ENG

1900A-R40-A500

80311-TK4-A010HOSE CIMP

,SUCTION

7902A-TA5-2002HVAC CPU SUBASSEMBLY

7902A-STK-A400HVAC SUBASSY

Reduction in dumpster size allows team to take ownership and verify contents promoting accountability.

Visual management

Plant – Styrofoam Recycle

AEP required packing material to build ahead FHEV engine 

blocks for build out.‐MAP stored/returned Styrofoam engine base blocks for reuse. AEP returned to MAP for recycling in MAP Styrofoam Densifier. ‐ This activity had no input cost and saved AEP from purchasing temporary packaging material.

Cooperation among plants and within plants

Communication Link

Internal communication within departments

Internal communication – associate magazine

OEPA Encouraging Environmental Excellence “Gold” Level Recognition of all 3 HAM Plants

AEP Team ELP Team MAP Team

www.honda.com/environment

Environmental ReportingIn 2005, Honda published our first North America

Environmental report.

Are there any questions ?

Robert BottomHonda of America, Mfg., Inc.

24000 Honda ParkwayMarysville, OH 43404

937-644-6415robert_bottom@ham.honda.com