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GKN Driveline
GKN Driveline Sanford Precision Forming Facility
Plant construction 1983
First production October 1984
Inital capacity of plant 4 million forgings / year
2005 output more than 12.2 million forgings
GKN Driveline
Our Product
Steel is the starting material
Forgings are made at PF
From forgings, CV joints are made at other GKN plants
GKN has more than 40% of the global market for CV joints
GKN Driveline
HR-EHS-014 / January 2, 2001 / Rev. Date: 5/5/04
EHS PolicyAt GKN Driveline, we are committed to maintaining a high standard of environmental,
health, and safety (EHS) performance by the establishment and review of objectives and targets by corporate management. We also are committed to creating and promoting a safe and healthy working environment by implementing accident
prevention programs, encouraging safe work practices, and by systematic and active management of risk in all areas of our business.
We strive to comply with all applicable EHS regulations, GKN policies, and other requirements to which we subscribe. We will ensure prompt correction of non-
compliant issues.
We are dedicated to the prevention of pollution, reduced emissions to air, land, water, and to the conservation of natural resources. We encourage the development of waste reduction partnerships with employees, suppliers, and customers. We will
continually improve actions that reduce risks, accidents, and minimize negative EHS impact.
GKN Driveline
ENERGY CONSUMPTION
OUR SIGNIFICANT ENVIRONMENTALASPECTS & IMPACTS
WATER CONSUMPTION
ISO14000 ENVIRONMENTAL MANAGEMENT SYSTEM
WASTE GENERATION
GKN Driveline
Corporate Target
Site Target
Corporate target: 10% reduction from 1999 baseline
Site target: 18.65% reduction from 1999 baseline
Energy ConsumptionKWh per 100,000 Pieces Produced
0
50,000
100,000
150,000
200,000
250,000
300,000
350,000
Jan
Feb Mar Apr MayJu
ne July
Aug Sept
OctNov Dec YTD19
9920
04
Energy Usage (KWh) Energy Target (KWh)
Corporate Target
Site Target
GKN Driveline
Corporate target: 10% reduction from 1999 baseline
Site target: 17.75% reduction from 1999 baseline
Water ConsumptionCubic Meters per 100,000 Pieces Produced
0.0050.00
100.00150.00
200.00250.00
300.00350.00
400.00450.00
Jan
Feb Mar Apr MayJu
ne July
Aug Sept
OctNov Dec YTD19
9920
04
Water Usage (Cubic Meters) Water Target (Cubic Meters)
Site TargetCorporate Target
GKN Driveline
Corporate target: 5% reduction from 1999 baseline
Site target: 48.14% reduction from 1999 baseline
Waste GenerationMetric Tonnes per 100,000 Pieces Produced
0.000.501.001.502.002.503.003.504.004.505.00
Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec YTD 1999 2004
Solid Waste (Metric Tonnes) Solid Waste Target (Metric Tonnes)
Site Target
Corporate Target
GKN Driveline
Earth Day Celebration
An opportunity to renew our pledge to minimize the impacts of our significant aspects—energy, water, and waste
Employees reviewing Earth Day displays
GKN Driveline
State-of-the-Art Emissions Control System
The Rotoclonescrubber combines centrifugal force and mixing of water and dust-laden air
Only forging plant in the world that has applied this technology to control warm form press emissions
Rotoclone scrubber replaced the wet scrubber system although compliance was fully achieved with the wet scrubber system
GKN Driveline
Debottlenecked Waste Water Treatment Plant
The Waste Water Treatment plant project was debottlenecked to ensure zero non-compliance at all times
The limitations of the previous plant were flow and zinc content. But the new plant was over-designed on purpose to accommodate stewardship features, e.g., drier filter cake, lower toxic levels, and equalized flow.
GKN Driveline
Value Stream Management (VSM) CellThe VSM cell reduced material movement by streamlining the cold forming operation
Phosphate treatment is one of the main contributors of environmental pollution. The VSM cell eliminates phosphate treatment.
The VSM cell results in significant reduction of energy, water, and waste—our significant ISO 14000 aspects and impacts.
GKN Driveline
Recycling Projects
• Computer and photocopier paper
• Plastic bottles
• Aluminum cans
• Chemical drums
• Aerosol cans
• Used oil
• Wood pallets
• Fluorescent lamps
• Steel scrap
COMPLETED
GKN Driveline
Other Stewardship InitiativesGKN is one of the few companies that tracks CO2 emissions from transportation of raw materials and products (Global Warming/Kyoto Protocol)
We meet with the City of Sanford to pro-actively address compliance issues
Various parameters of our storm water are monitored on a daily to weekly schedule (our permit requires semi-annual monitoring only)
We are actively pursuing a project for incorporating waste watertreatment sludge into building materials (instead of landfilling)
GKN Driveline
Sustainable DevelopmentENVIRONMENT ECONOMY
COMMUNITY
GKN’S CORPORATE POLICY EMBRACES HARMONY BETWEEN THE ENVIRONMENT, THE ECONOMY, AND THE COMMUNITY
GKN Driveline
Greening Sanford
GKN Driveline employees planted trees at Depot Park, Sanford (Sanford Herald,
April 17, 2005)
GKN Driveline
Benchmarking for Environmental Stewardship
The GKN PF plant is routinely benchmarked by forging operations all over the world
We have benchmarked environmental management systems of Toyota, Moen, and others
In return our environmental management system was benchmarked by NACHI, Lee Iron and Brick, Caterpillar, and others
Our corporate website provides internal benchmarking opportunities on our best management practices for environmental systems
GKN Driveline
Other Community Initiatives
Presentation of our environmental policy and environmental management system to the Mayor and his City Council members
Partnership with NC State University on energy audit
Partnership with NC Solar Center, State Energy Office, and San Diego Power for energy reduction measures
Partnership with supplier IMDS program for greening the supply chain
GKN Driveline
Integration EffortsEnergy, water, and waste evaluations in our capital investment decisions (e-works software for CAPEX decisions)
Kaizen (continuous improvement) initiatives that won top award for EHS innovation in 2002, and local management award in 2003 and 2004
Communication of ISO 14000 objectives and targets:Monthly meeting with local management
•Monthly meeting with top management
•Quarterly environmental report to corporate
•Annual environmental report to corporate
GKN Driveline
Integration EffortsSite environmental goals and objectives are integrated with corporate loss prevention and risk assessment approach (through use of corporate-sponsored ENGAGE software)
Corporate “Green Scheme” program fosters innovation in environmental management systems, and provides a significant opportunity for benchmarking best management practices
Quarterly and annual environmental reports are submitted to corporate addressing environmental management system conformance with ISO 14000 standards
GKN Driveline
Integration Efforts•ISO 14000 steering committee, non-conformance forms, behavioral surveys
•ISO 14000 training and awareness campaigns
•ESCARs (corrective and preventative actions program)
•Rewards and recognition program
•Partnership with suppliers and contractors—review of EMS information at the security gate, contractor video
GKN Driveline
Incentives for Meeting Objectives and Targets
•Bonus package for management is linked to meeting ISO 14000 objectives and targets
•Incentives package for employees is linked to overall achievement of EHS metrics (including ISO 14000 objectives and targets)
•Spot awards for submitting exceptional environmental recommendations for meeting ISO 14000 objectives and targets
GKN Driveline
Going into the Future…..
•More recycling projects: Toner cartridges, Batteries, Oil absorbents, Gloves, Aprons
•Carpooling
•Further awareness through ISO 14000 puzzles and behavioral surveys
•Water-based parts cleaners (instead of solvent-based)
•Kamishibai audits for our environmental system
•Green supply chain
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