GREEN TEAM
Freightliner Custom
Chassis Corporation’s
Zero Waste to Landfill
Journey
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
The Evolution of Environmental
Responsibility at FCCC
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
Who We Are
•Freightliner Custom Chassis Corporation (FCCC) was
formed in 1995 after Freightliner Corporation (now
Daimler) acquired the Chassis Division of Oshkosh
Corporation
•289,000 sq. ft. facility
• 75 acres offering 227,400 sq. ft. of manufacturing
and 33,600 sq. ft. of research, dynamometer and
paint processes
•Employs 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
What We Do
•FCCC manufactures Class 4 - 8 chassis for
motorhomes, walk-in vans, commercial buses and
school buses
552 Hyatt Street, Gaffney South Carolina 29341
FCCC Aerial Photo
FCCC Customers
GREEN TEAM
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
552 Hyatt Street, Gaffney South Carolina 29341
Awards and Recognition
GREEN TEAM
The FCCC manufacturing facility served as the pilot plant for the Zero Waste
to Landfill project initiated by DTNA. Awards and recognition:
FCCC won the 2009 Daimler Environmental Leadership
Award, presented in Stuttgart, Germany on March 25,
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 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 South Carolina Smart Business Recycling
Program and was awarded in 2010 for its outstanding waste reduction and
recycling efforts.
552 Hyatt Street, Gaffney South Carolina 29341
Awards and Recognition
GREEN TEAM
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
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
Motivation for Implementation
Daimler’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
400,000
337,320
350,000
316,320
300,000
250,000
309,900
287,320
287,480
284,080
246,160
251,060
228,580
219,320
Lbs.
214,140
196,560
200,000
150,000
100,000
50,000
0
Jan06
Feb06
Mar06
552 Hyatt Street, Gaffney South Carolina 29341
Apr06
May06
Jun06
Jul-06
Aug06
Sep06
Oct06
Nov 06
Dec06
GREEN TEAM
Zero Waste to Landfill Efforts:
•
•
2007 Solid Landfill Waste:
- 100.37 pounds per chassis built
2008 Solid Landfill Waste:
- 35.57 pounds per chassis built
•
Recycling Containers on Production Line
2009 Solid Landfill Waste:
- 8.39 pounds per chassis built
•
•
76.4% solid landfill waste reduction in 2009 vs. 2008
96.5% solid landfill waste-free in 2009
Recycling scrap metal
552 Hyatt Street, Gaffney South Carolina 29341
Returnable Packaging
Recycling plastic at satellite facility
Community Partnerships
GREEN TEAM
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.
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
Solid Waste to Landfill Totals
160,000
140,000
120,000
LBS.
100,000
80,000
60,000
40,000
20,000
0
8
9
8
9
8
9
8
9
9
8
8
8
8
9
8
8
9
8
9
08
09
09
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-0
-0
-0
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-0
-0
-0
-0
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-0
l-0
r-0 ay-0
r-0 ay-0
t-0
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M
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A
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M
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MONTHS
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
Financial Impact of Waste
Reduction/Recycling
2007 Waste/Recycle Totals
TOTAL
ACTUAL TOTAL COST
Weight
8,188,958
Waste Totals
Recycling Totals
TOTAL (lbs)
% Landfill Waste Free
% Recycling Rate
2,274,710
5,914,248
8,188,958
72.2%
72.2%
2009 Waste/Recycle Totals
TOTAL (lbs)
ACTUAL TOTAL COST
Weight
2,743,034
Waste Totals
Recycling Totals
TOTAL (lbs)
% Landfill Waste Free
% Recycling Rate
97,100
2,645,934
2,743,034
96.5%
94.8%
2011 Waste/Recycle Totals
TOTAL (lbs)
ACTUAL TOTAL COST
Weight
3,123,058
Waste Totals
Recycling Totals
TOTAL (lbs)
% Landfill Waste Free
% Recycling Rate
0
3,123,058
3,123,058
100.0%
98.0%
552 Hyatt Street, Gaffney South Carolina 29341
Cost
$137,006.55
$59,763.32
Cost
$24,176.04
Cost
$25,609.27
Rebate
$77,243.23
Rebate
$26,404.91
$2,228.87
Rebate
$79,603.04
$53,993.77
2008 Waste/Recycle Totals
TOTAL (lbs)
ACTUAL TOTAL COST
Weight
4,661,947
Waste Totals
Recycling Totals
TOTAL (lbs)
% Landfill Waste Free
% Recycling Rate
583,340
4,078,607
4,661,947
87.5%
87.5%
2010 Waste/Rec Totals (ytd - 9/30)
TOTAL (lbs)
ACTUAL TOTAL COST
Weight
2,588,491
Waste Totals
Recycling Totals
TOTAL (lbs)
% Landfill Waste Free
% Recycling Rate
0
2,588,491
2,588,491
100.0%
97.6%
Cost
$86,349.97
$12,745.76
Rebate
$73,604.21
Cost
$6,808.65
Rebate
$29,749.54
$22,940.89
100.0%
80.0%
60.0%
FCCC Recycling Rate
40.0%
20.0%
0.0%
2006
2007
2008
2009
2010
2011
GREEN TEAM
Our Journey to ZWTL
FCCC
selected as
DTNA pilot
facility for
Zero Waste
Initiative.
Sept
2007
Finalized details
with contractors
for remaining
waste stream
recycling.
Founded FCCC
“Green Team”
and Launched
FCCC Env.
Webpage on
FCCC Online.
Oct
2007
Nov
2007
Dec
2007
Registered for
EPA WasteWise
partnership.
58% reduction in waste
to landfill/EQU versus
same time in 2007.
94.1% solid waste
landfill free for
September.
62.3% reduction in
waste to landfill/EQU
versus 2007 baseline.
FCCC awarded by
South Carolina
Smart Business
Recycling for 2009
Plastics/Rubber
recycling programs
implemented.
Jan
2008
Feb
2008
Mar
2008
Began use of
recycling
centers in
canteen
areas.
April
2008
Visited Subaru
(Indiana) to
review waste
reduction
program.
Accepted as
partner to EPA
WasteWise
program.
Recognized by EPA
WasteWise for 2007
waste reductions.
42% reduction in waste to
landfill/EQU versus same
time in 2007.
552 Hyatt Street, Gaffney South Carolina 29341
May
2008
June
2008
July
2008
Aug
2008
Sept
2008
Facility-wide
implementation
of current
comprehensive
recycling
programs.
Oct
2008
FCCC partnership
with Gaffney High
School to promote
waste reduction
Nov
2008
Dec
2008
Jan - Sept
2009
FCCC reaches
Zero Waste to
Landfill
Oct
2009
Goal of zero waste to
landfill for FCCC
facility (Jan 2010).
FCCC recognized as
members of SCEEP
and SC Smart
Business Program
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.
FCCC achieves 97.3%
landfill waste free
status for the month of
July
Traditional Practices
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.
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
FCCC Green Team
GREEN TEAM
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.
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.
552 Hyatt Street, Gaffney South Carolina 29341
Communication
GREEN TEAM
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?”
FCCC Green Team
SharePoint
552 Hyatt Street, Gaffney South Carolina 29341
What do we already do?
February 2008 – You can’t eliminate
something if you do not know that it exist.
GO & SEE
DUMPSTER DIVE
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
What do we already do?
GREEN TEAM
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.
552 Hyatt Street, Gaffney South Carolina 29341
Lets Get Started!
GREEN TEAM
February/March 2008 – Standardized identification was needed to easily identify recycling
opportunities
Standardization Chart
42% WTL reduction
552 Hyatt Street, Gaffney South Carolina 29341
Lets Get Started!
March 2008 – Implementation in Canteen and Break Areas
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
GREEN TEAM
Other Reduction Opportunities
2008 – Corporate Returnable Packaging; Reduction of waste in restrooms
552 Hyatt Street, Gaffney South Carolina 29341
Borrow Proudly
GREEN TEAM
April 2008 – Benchmark and BORROW PROUDLY! We borrowed from “The Best”.
552 Hyatt Street, Gaffney South Carolina 29341
Sorting at Point of Use
GREEN TEAM
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.
552 Hyatt Street, Gaffney South Carolina 29341
Sorting at Point of Use
GREEN TEAM
May-August 2008 – Plastics are collected in easily recognized color containers from
point of use to centralized collection locations.
552 Hyatt Street, Gaffney South Carolina 29341
Sorting at Point of Use
GREEN TEAM
May-August 2008 – Plastics are sent to South Carolina Vocational Rehabilitation for
further segregation to increase our recycling rebates.
552 Hyatt Street, Gaffney South Carolina 29341
Partnerships Made
GREEN TEAM
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.
552 Hyatt Street, Gaffney South Carolina 29341
Benefits of Recycling
GREEN TEAM
2008 – Scrap rubber hoses is recycled to manufacture playground mulch and other
products, all made from 100% recycled rubber.
552 Hyatt Street, Gaffney South Carolina 29341
Spread the Culture
GREEN TEAM
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.
552 Hyatt Street, Gaffney South Carolina 29341
End in Sight
GREEN TEAM
October 2009 – A newly developed partnership with VLS Recovery provided our last
need to remove the “leftovers” from the landfill.
Poor attention to detail allowed recyclables to end up in local landfills. Compactor emptied 1-2
times daily at transfer site.
552 Hyatt Street, Gaffney South Carolina 29341
General non-recyclable waste sent to LAST landfill transfer site drop. This load consisted of 5
weeks of non-recyclable waste.
Celebrate Success!!!
GREEN TEAM
October 2009 – FCCC celebrated the success of achieving ZERO Waste to Landfill!!!!
552 Hyatt Street, Gaffney South Carolina 29341
Covering Sustainability
GREEN TEAM
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.
552 Hyatt Street, Gaffney South Carolina 29341
Covering Sustainability
GREEN TEAM
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
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
Covering Sustainability
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.
SIX SIGMA GREEN BELT PROJECT
PROBLEM: 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.
ITEM
Explanation of Cost
We currently have 400 shop floor employees who are required to
use a stamp or PPAF sign off. Cost/stamp is $5.
Custom folders we currently use cost FCCC $.65/folder. 16,000
trucks in 2008.
Cost Savings
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
Banker Boxes
150 folders/box. 12 boxes cost $80.
Stamps
Folders
$2,000.00
$10,400.00
$720.00
TOTAL:
$19,754.29
OTHER BENEFITS:
1
Forces the PPAF to be correct in station (FCCC spends approx 42 hrs/week chasing PPAF discrepancies (Annual Cost $98,280).
2
The storage cost at Iron Mountain would be eliminated or reduced.
552 Hyatt Street, Gaffney South Carolina 29341
GREEN TEAM
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
552 Hyatt Street, Gaffney South Carolina 29341