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The Electroplating Sector: Compliance Assistance, Enforcement, and Pollution Prevention

The Electroplating Sector: Compliance Assistance, Enforcement, and Pollution Prevention. COMPANY OVERVIEW. Elizabethtown, KY USA. OUTLINE. Location: Elizabethtown, Kentucky Ownership: 100% Akebono Brake Corporation Incorporated: July 18, 1986 SOP: May 1988 (GM, HONDA)

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The Electroplating Sector: Compliance Assistance, Enforcement, and Pollution Prevention

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  1. The Electroplating Sector: Compliance Assistance, Enforcement, and Pollution Prevention ISO/TS 16949-2002 ISO 14001

  2. COMPANY OVERVIEW Elizabethtown, KY USA ISO/TS 16949-2002 ISO 14001

  3. OUTLINE • Location: Elizabethtown, Kentucky • Ownership: 100% Akebono Brake Corporation • Incorporated: July 18, 1986 • SOP: May 1988 (GM, HONDA) • Land Size: 55 Acres • Building Size: 348,000 SQ FT • Associates: 1,157 Total [ January 2007) • Work Schedule: 3 Shift/5 Day, Weekend Crews (3d/12 hr) “ ISO/TS 16949-2002 ISO 14001

  4. AKEBONO ENGINEERING CENTER AKEBONO BRAKE – ELIZABETHTOWN PLANT AKEBONO BRAKE – GLASGOW PLANT AKEBONO BRAKE – SPRINGFIELD PLANT AKEBONO BRAKE CORPORATION North American Facilities • AKEBONO BRAKE – ELIZABETHTOWN PLANT, KY (1988) • AKEBONO BRAKE – GLASGOW PLANT, KY (1994) • AKEBONO ENGINEERING CENTER, MI (1998) • AKEBONO BRAKE – SPRINGFIELD PLANT, KY (2001) ISO/TS 16949-2002 ISO 14001

  5. DAILY PRODUCTION VOLUMES(BASED ON 2006 AVG.) FRONT & REAR CAST IRON CALIPERS 27,500/DAY REAR INTEGRAL CALIPERS 2,500/DAY REAR ALUMINUM CALIPERS 3,500/DAY REAR DRUM BRAKES 11,000/DAY PAD ASSEMBLIES 55,000/DAY ISO/TS 16949-2002 ISO 14001

  6. PRODUCTS FRONT & REAR CAST IRON CALIPERS (SINGLE & DUAL PISTON) REAR INTEGRAL & ALUMINUM CALIPERS (SINGLE & DUAL PISTON) REAR DRUM BRAKES (DUO-SERVO & PARKING) FRONT & REAR PAD ASSEMBLIES NAO - (NON-ASBESTOS ORGANIC) ISO/TS 16949-2002 ISO 14001

  7. CUSTOMER BASE - DOMESTICS Malibu (Ft/Rr Caliper/Pad) Lacrosse (Rr Caliper/Pad) Rendezvous (Rr Caliper/Pad) Saturn Red Line (Fr Caliper/Pad) Opel GT (Ft Caliper) G6 (Ft/Rr Caliper/Pad) Pontiac Pursuit (Fr Caliper/Pad) Chevy Impala (Rr Caliper/Pad) Cadillac DTS (Rr Caliper) Solstice (Ft Caliper) Cobalt(Ft Caliper/Pad) Monte Carlo (Rr Caliper/Pad) LeSabre (Rr Caliper) Saturn Ion(Ft Caliper/Pad) Grand Prix (Rr Caliper/Pad) Saturn Sky (Ft Caliper) HRR (Ft Caliper/Pad) ISO/TS 16949-2002 ISO 14001

  8. CUSTOMER BASE - DOMESTICS Chevy Uplander (Rr Caliper) Chevy Trailblazer (Rr Pad) Chevy Express (Rr Caliper/Pad) Ford Econoline (PKB) Buick Terraza (Rr Caliper) Envoy (Rr Pad) Chevy Savanna (Rr Caliper/ Pad) Saturn Relay (Rr Caliper) Suburban (Rr Caliper/Pad) Pontiac Montanna (Rr Caliper) Chevy Tahoe (Rr Caliper/Pad) ISO/TS 16949-2002 ISO 14001

  9. CUSTOMER BASE - TRANSPLANTS HONDA Toyota/NUMMI MITSUBISHI MDX (Rr Caliper/Pads & PKB) Civic (Ft Calipers/Pads) Corolla (100%) Vibe (Ft Caliper, Drum Brake) Galant (100%) Ridgeline (Ft Caliper/Pads, Rr Pads & PKB) Accord (Ft Calipers/Pads) Avalon (Rr Caliper) Tundra (Rr Caliper) Eclipse / Spyder (100%) Acura TL (Ft Pads) Element (Ft Calipers/Pads) Solara (Rr Caliper) Endeavor (PKB) Matrix (Ft Caliper, Drum Brake) Pilot (100%) ISO/TS 16949-2002 ISO 14001

  10. DA5 Piston DA82 Machining DM3 DM7 HP10 Grinder/Scorcher HP8 CO5 CO5 CO4 HP9 DA81 DM5 DA3 DA7 DA80 ST2 DA4 HP3 BP70 DM2 DM6 BP73 HP2 CO1 MP1 BP71 HP1 DM4 DA2 DA6 SL62 SL60 FB3 US51 BP72 SL61 ST1 FB2 FB1 DM1 CO3 US50 US52 DM9 DM10 DM12 DM11 US53 DA1 CO2 PLANT LAYOUT Aluminum Disc Brake Drum Brake/Piston Friction Drum Office Friction QC Office Orbit- form Mix & Blend Shipping & Receiving Docks Friction Office MDC Shim/ Bond DA14 Paint CAFETEREIA/APS DA13 Piston Finishing SERVICE PDA DA12 Nickel Platter DA11 - E Platter DA10 DA9 Piston Machining Disc / Store Maintenance DA15 DA8 EDP Piston sub- assembly SL63 / 64 DM17 DM16 Store General HP6 HP7 Paint AD 66 / 67 DM13 DM8 Phosphator Grinder/Scorcher HP5 HP4 DM15 DM14 Die Kaizen Area Quality Assurance Maintenance Disc Office CAFETERIA Front Office 1 ISO/TS 16949-2002 ISO 14001

  11. WATERCONSERVATION Conductivity Flow Control of Rinse Water Volume Counter Current Rinse Tanks on Metal Finishing Lines Flow Restriction Devices on Individual Rinse Tanks ISO/TS 16949-2002 ISO 14001

  12. Conductivity Flow Control of Process Rinse Water ISO/TS 16949-2002 ISO 14001

  13. Conductivity Meter ISO/TS 16949-2002 ISO 14001

  14. Calibration of Conductivity Meter ISO/TS 16949-2002 ISO 14001

  15. First Stage Rinse Tank ISO/TS 16949-2002 ISO 14001

  16. Final Stage Rinse Tank ISO/TS 16949-2002 ISO 14001

  17. Two Stage Conductivity Controlled Rinse Tanks ISO/TS 16949-2002 ISO 14001

  18. CONDUCTIVITY FLOW CONTROL OF RINSE WATER VOLUME Flow Control Based on Conductivity of First Stage Rinse Tank of Counter Current Application Conductivity Set Point Determined by Analysis of Rinse Water and its Effect on Painting Quality Rinse Water Reduced in Painting Operation From 7,000 gpd to 2,500 gpd ISO/TS 16949-2002 ISO 14001

  19. Two Stage Counter Flow Rinse ISO/TS 16949-2002 ISO 14001

  20. KPPC ENERGY EFFICIENCY ASSESSMENT REPORT • Major Energy Consuming Equipment: >10 h.p. • Energy Bill Analysis • Energy Management Opportunities • Financing Options ISO/TS 16949-2002 ISO 14001

  21. ENERGY MANAGEMENT OPPORTUNITIES • Installation of infrared ovens • Recover waste heat from air compressors • Tie HVAC units into Trane Tracer Summit • Repair compressed air leaks • Install power factor correction banks • Replace 250W high pressure sodium fixtures • Install occupancy controls on facility lighting • Replace compressed air agitators in plating tanks ISO/TS 16949-2002 ISO 14001

  22. CURRENT ENERGY MANAGEMENT PRACTICES • Use outside air for compressor intake • Purchase premium efficiency motors • Reduce steam pressure from 100psi – 80 psi • Use infrared ovens • Use timers on conveyor motors • Reduction in compressed air pressure ISO/TS 16949-2002 ISO 14001

  23. BEFORE- Description: Electric Service Entrance Problem: Power Factor below 90% resulting in penalty charge on electric bill INCREASE THE CAPACITOR BANK ON ELECTRICAL SERVICE ENTRANCE ISO/TS 16949-2002 ISO 14001

  24. AFTER: Description: Electrical service entrance with additional 300 KVAR capacitor bank Savings: Energy charges reduced $ 9,580.00 annually INCREASE THE CAPACITOR BANK ON ELECTRICAL SERVICE ENTRANCE ISO/TS 16949-2002 ISO 14001

  25. BEFORE: DESCRIPTION: Boiler #1 fire tubes during annual inspection PROBLEM: Wasted heat results in higher gas stack gas temperatures and heat loss IMPROVE EFFICIENCY OF PROCESS STEAM BOILERS ISO/TS 16949-2002 ISO 14001

  26. AFTER: DESCRIPTION: Installation of “ fuel saver” turbulators reduce lost heat COST SAVINGS: An annual energy savings of $ 9,940 was realized in reduced energy usage. IMPROVE EFFICIENCY OF PROCESS STEAM BOILERS ISO/TS 16949-2002 ISO 14001

  27. Brake pads exiting the powder paint spray booth make their way by conveyor toward the infrared cure oven ISO/TS 16949-2002 ISO 14001

  28. EUROPEAN UNIONSUBSTANCES OF CONCERN • In August of 2002, ABE began the conversion from hexavalent to trivalent chromium solutions on the first of ten zinc plating processes. • Since 2002, seven zinc plating system have been converted to trivalent chromium with the remaining systems planned for completion by July 2007. ISO/TS 16949-2002 ISO 14001

  29. The interior of a zinc plating system where trivalent chromium is applied to a disc brake ISO/TS 16949-2002 ISO 14001

  30. PROCESS MODIFICATIONS • In 2003 , ABE installed its first powder paint system to begin the phase out of the solvent based painting process for pressure plates. • Powder paint Line 2 was installed in April 2005 to complete the removal of four solvent based painting systems ISO/TS 16949-2002 ISO 14001

  31. ENVIRONMENTAL BENEFITS • A reduction of 6 tons / year of VOC and HAP emissions were realized with this process change • 15 tons / year reduction in hazardous waste generated from the liquid paint process from 2003 thru 2006 ISO/TS 16949-2002 ISO 14001

  32. ISO/TS 16949-2002 ISO 14001

  33. ELECTROLESS NICKEL PLATINGBATH TREATMENT Reduce Nickel Concentration by 90% in Spent Plating Baths Prior to Discharge into Onsite Pretreatment Plant Plate Out the Spent Bath on Metal Shavings Generated from the Manufacturing of Pistons used in the Disc Brake Applications Nickel Coated Metal Shavings Sent to Recycling Facility ISO/TS 16949-2002 ISO 14001

  34. ISO/TS 16949-2002 ISO 14001

  35. ISO/TS 16949-2002 ISO 14001

  36. ISO/TS 16949-2002 ISO 14001

  37. Akebono – Elizabethtown Plant received the inaugural Kentucky Excel award in May 2006 at the Master Level Akebono- Glasgow Plant Received the the Kentucky Excel award in April 2007 at The master level. Akebono- Springfield Plant Received the Kentucky Excel Award in April 2007 at the Leadership level. ISO/TS 16949-2002 ISO 14001

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