Seventy-Third Meeting of the Advanced Manufacturing Forum

Journey to Lean and Green Manufacturing

April 4-5, 2013
Toftrees Golf Resort & Conference Center


DuPont Building Innovations Achieves Zero Landfill Status
David L. Walter, Strategic Project Leader E. I. DuPont de Nemours & Co., Wilmington, DE

DuPont has been bringing world-class science and engineering to the global marketplace since 1802. DuPont Building Innovations is one of 13 business units inside of DuPont, and brings dynamic science to the development of innovative products and services for the building industry. The Building Innovations business sent 81 million pounds of manufacturing waste to landfill in 2008 from the creation of DuPont™ Tyvek®, Corian®, and Zodiaq® in 15 locations around the world. A Six Sigma team was assigned to find ways to reduce, reuse, or recycle all of the waste by the end of 2011. All 15 manufacturing locations achieved zero landfill status. This presentation will focus on what was done and how.

Columbia's Investments for the Future
Ali Salehi, Senior Vice President of Engineering & Operations
Columbia Manufacturing, Inc.
, Westfield, MA

Columbia Mfg. Inc., a 136 year old manufacturing company, was the first manufacturer of bicycles in America and is now producing the finest classroom furniture in the country. In 1991, the company was forced into bankruptcy as a result of less expensive imports of foreign bicycles and other factors, and emerged from bankruptcy with a vibrant and forward-thinking new business plan. The company made substantial investments to eliminate its spray paint lines and all VOCs, followed by the first closed-loop, permit-free nickel chrome plating system in the country.

This presentation will focus on how the company’s innovative thinking reduced its chrome usage by 93%, water consumption by 147,000 gallons/day, eliminated all fuel oil burning boilers and is recycling all its wood, steel and paper products, along with challenges and issues the company faced along the way. Today, despite a downturn in the economy, Columbia has gained more market share in the industry and is looking forward to the future.

Implementing Ford's Manufacturing Sustainability Vision
Lisa Hansen, Manager of Technical Services, Environmental Quality Office
Ford Motor Company
, Dearborn, MI

Ford Motor Company is a global automotive company and a leader in sustainable initiatives. Our strategy is based on our One Ford plan, the outcomes of which we define as Great Products, Strong Business, and Better World. Our products have to leverage the latest technology, offer outstanding quality and reliability, and excite the imagination of consumers.

Great products lead to profitable growth and a strong business that continues to invest in innovation and the development of more outstanding products. This, in turn, sets the stage for Ford to contribute to a better world by reducing the footprint of our products and operations. For example, we increased the use of sustainable materials in our vehicles and reduced tailpipe emissions. In our manufacturing plants, we reduced waste to landfill, water use, energy use, and volatile organic compound (VOC) emissions. This presentation will discuss Ford’s achievements at our manufacturing facilities, including innovative technologies and processes that were deployed, and identify the challenges we face as new ideas are identified.

Welcome to Samsung
Michael Moss, Director of Corporate Environmental Affairs
Samsung Electronics North America
, Pine Brook, NJ

For over 70 years, Samsung has been dedicated to making a better world through diverse businesses. Through innovative, reliable products and services, talented people, a responsible approach to business and global citizenship, and collaboration with our partners and customers, Samsung is taking the world in imaginative new directions.

Samsung is also stepping up strongly in the environmental space in the U.S. For example, while Samsung is a market leader in television and other consumer electronics, Samsung is leading the way forward in responsible e-waste recycling. Over the past four years, Samsung has responsibly recycled 1/4 billion pounds of e-waste in the U.S. alone, satisfying social and environmental needs to act. Let’s talk about how we (Samsung) began our recycling program based on principles; and then let’s put our thoughts together, as a group, for modeling both the recycling program and the supporting industry approach.