Pollution Prevention Case Study

Recycling and Source Reduction at the Ford Assembly Plant

DESCRIPTION OF THE FACILITY Ford Motor Company has manufactured and assembled over 10 million automobiles at the Chicago Assembly Plant since it opened in 1913. The plant, which produces the and from components manufactured at other locations covers 2.7 million sq. ft. and is traversed by a 23 mile-long assembly line. Activities performed at the plant include welding of sheet metal components to form vehicle bodies, the application of sealers and paint as well as installation of chassis, powertrain and trim components. With over 2,750 employees, Chicago Assembly produces more than 66 cars per hour and consistently ranks as one of the top North American automotive facilities in production as well as initial vehicle quality.

DESCRIPTION OF THE OPPORTUNITY BEING ADDRESSED The Chicago Assembly Plant is committed to protect the environment by striving to continually improve processes that minimize waste and pollution and by setting environmental objectives and targets, which meet or surpass legal expectations. One of the plant's significant environmental objectives has been the reduction in packaging waste and the volume of solid waste through collaborations with parts suppliers and outside contractors.

DESCRIPTION OF THE IMPROVEMENT In 1996, with the assistance of Waste Management, Inc., the Chicago Assembly Plant began a waste minimization program to reduce its manufacturing waste through source reduction and recycling actions. The project has focused on wooden pallets and cardboard waste and from 1996 through 1999, the source reduction and recycling of these materials has obviated their manufacture and disposal, thereby conserving the following resources1:

· 563,000 mature trees, 24% of which were saved by the reuse of 450,000 pallets at the plant.

· 11,165,000 gallons of oil, representing 252,000 barrels of No. 2 fuel oil, which could provide enough energy to heat and cool more than 51,600 homes for a year.

· 576,000 gallons of gasoline-enough to drive more than 13.4 million miles.

· 101,380,000 kW-hrs of electricity-enough power to fulfill the annual electricity needs of over SUBSTANCES: REDUCTION ACHIEVED: RECOVERY ACHIEVED: Wooden Pallets 2,070 tons 11,900 tons Cardboard packaging 333 tons 7,900 tons Solid Waste 4,280 tons --

ENVIRONMENTAL HIERARCHY LEVELS: Waste elimination

1 Each ton of fiber recycled conserves: 17 mature trees ; 464 gallons of oil; 24 gallons of gasoline; 4,210 kW-hrs of electricity; 7,000 gallons of water; 3.3 cubic yards of landfill airspace. Each ton of pallets recycled conserves 8.7 mature trees and 3.5 cubic yards of landfill volume. Source: U.S. Environmental Protection Agency, Ford Motor Company, Waste Management.