EATON%20-%20CUTLER-HAMMER%20Asheville,%20NC%20Plant

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EATON - CUTLER-HAMMERAsheville, NC Plant

• ENVIRONMENTAL MANAGEMENT PROGRAM

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ENVIRONMENTAL MANAGEMENT PROGRAM

• During the late 1980s the Asheville Plant
  embarked on a commitment to identify, evaluate
  and implement a waste minimization program. This
  has resulted in reduced volume of solid hazardous
  waste hauled offsite, reduced air emissions, and
  effluent discharges, energy and utilities
  conservation and successful recycling programs.

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ENVIRONMENTAL MANAGEMENT PROGRAM

• Reviews process that generate waste streams
• Develop means to reduce volume, quantity and
  toxicity of wastes generated.
• Research and implement new technologies that are
  environmentally acceptable.
• Employ housekeeping, maintenance, training and
  inventory control practices that support source
  reduction and pollution prevention.
• Continually strive to reduce all wastes.
• Implement recycling when opportunities are
  identified.

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ENVIRONMENTAL MANAGEMENT PROGRAM

• The environmental management successes for
  Cutler-Hammers Asheville manufacturing facility
  can be categorized under four headings.
• Electrical use
• Water use
• Natural gas use
• Environmental improvements

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ENVIRONMENTAL MANAGEMENT PROGRAM

• In mid 1998 the Cutler-Hammer Asheville Plant
  made a commitment to develop an EMS Program and
  pursue ISO 14001 Certification.
• The facilities environmental policy was
  constructed through a collaborative effort
  between top management and the EMS task force.

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Electrical Improvements

• Upgraded Office Lighting
• Installed Motion Sensors
• Discontinued In-House Furnace Brazing
• Compressed Air Upgrade
• Greenlights Survey
• Installed Energy Management System
• Changed Lighting Habits in Factory
• Time On / Time Off (Ownership)

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Electrical Improvements

• Changed Habits Turn machines, fans and task
  lights off when not needed.
• Discontinued use of infrared oven.
• Turn off PCs at end of work day.
• Applied for and received new tariff option with
  CPL. (LGS-RTP) Large general service - real
  time pricing
• Installed POW R command lighting panels.
• Installed programmable control of 17 HVAC Systems.

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Water Use Improvements

• Replaced liquid coolant with cold air guns for
  milling, drilling and band saws.
• Replaced water-cooled compressors with air
  cooled.
• Replaced large cooling tower with 3 small
  chillers.
• Received exemption from mandatory surcharge
  imposed by the Water Authority during draught.
  Displayed documented conservation / reduction
  success during prior 12 months.

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Water Use Improvements

• Cut back volume on sinks, Bradley basins and
  toilets.
• Installed new flush valves.
• Posted conservation notices on restroom doors.
• Communicated daily draught status with tips in
  daily bulletins.
• Further tweaked counter-flowing and volume at
  Paint Line Pretreatment.
• Extended interval on dumping cleaner tanks
  (without sacrificing quality)

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Natural Gas Improvements

• Added insulation during re-roofing in 1993.
• Building heat retention improved
• Boilers operate less
• Using recovered heat off air-cooled compressors
  to help heat plant.
• Annual inspection on boiler burners, Paint Line
  oven burners and pretreatment burners to maintain
  peak performance.
• Renegotiated class of service with Gas Company.
  Combined two services into one.
• Started purchasing transportation gas through a
  broker at City Gate.
• Fixed gas prices for multiple months.

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Environmental Improvements

• Discontinued in-house furnace brazing.
• Discontinued use of Cadmium, Silver, Tin and Zinc
• Converted from Xylene base to Polyester base
  varnish.
• Changed from foam packaging to recyclable paper
  Pad-Pac packaging.
• Eliminated aerosol cans as a disposable hazardous
  waste.
• Converted from Electro-Coat painting to Power
  Coating.
• Discontinued in-house Electroplating.
• Discontinued use of Over-Spray Paint Booth.
• Eliminated need for Waste Water Treatment.

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Baseline of Implementation

• ISO 9000 Facility
• Strong Environmental Compliance Programs in Place
• Functional Emergency Response Team

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The Certification Process

• We identified the major tasks that must be
  completed to obtain certification and set target
  dates for completion.
• 1. Write Environmental Policy 10/15/98
• 2. Form Implementation Task Force 10/15/98
• 3. Formal Training for Task Force 10/27/98
• 4. Management Overview of the ISO
  Standard 10/27/98
• 5. Identify Significant Environmental
  Aspects 12/01/98
• 6. Identify Significant Environmental
  Impacts 12/01/98
• 7. Gap Analysis 12/01/98
• 8. Write Environmental Management Manual 12/30/98
• 9. Set Environmental Objectives and
  Targets 01/04/99
• 10. Write Procedures for Achieving Obj. and
  Targets 01/04/99

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The Certification Process (Cont.)

• 11. Lead Assessor Training 02/15/99
• 12. Internal Auditor Training 02/15/99
• 13. Communicate Environmental Procedures/Policy 03
  /15/99
• 14. Internal Audits 03/15/99
• 15. Management Review of ISO 14001 05/07/99
• 16. Pre-Registration Audit 05/20/99
• 17. Registration Audit 06/22/99

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Environmental Policy

• The Cutler-Hammer Asheville Plant, a manufacturer
  of electrical distribution equipment, is
  committed to prevent pollution and to the
  continual improvement of its Environmental
  Management System. We commit to comply with all
  relevant Federal, State, and Local environmental
  laws and regulations and to follow corporate
  environmental guidelines as they apply to our
  business. We further commit to use energy
  efficiently and to reduce, reuse or recycle
  materials in an effort to conserve natural
  resources. We will continually strive to be a
  good corporate neighbor, to be involved in
  community activities that positively impact the
  environment and to use environmentally friendly
  products in the design and manufacture of our
  product.

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EMS Design

• Simple but Effective
• When writing your EMS manual, dont promise a lot
  of things that you cant deliver or that would be
  difficult to keep going. (e.g. We will test our
  Emergency Preparedness Plan weekly.) What you
  want to do is to test your Emergency Preparedness
  Plan as often as you feel is necessary for the
  plan to be effective and state that in your
  manual.

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EMS Design

• Environment or Auditor
• During the process you must constantly question
  if what you are doing is for the environment or
  the ISO auditor. Sometimes it is easy to get
  carried away and forget the main focus of ISO
  14001.

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EMS Design

• Design a System
• You must constantly ask yourself, am I putting an
  EMS System together or am I just coming up with
  pieces that will never fit together. If you
  dont put a system together, you will constantly
  have to message the EMS to make it work -
  especially at periodic audit (6 month) time.
• Use ISO 9000 programs.

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EMS Design

• Pollution Prevention
• Determine all of your environmental impacts.
  This is where pollution takes place.
• Have a good method to determine significance.
  This is where the most pollution takes place.
• Operational Controls - This is where pollution is
  prevented.

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EMS Design

• Operational Controls
• More non-conformity is written against this
  element than any other.
• Should have documented work instructions. (Not
  required by ISO but a good idea.)
• Must have a way to monitor and measure
  operational controls.

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Example

• Aspects
• Storage disposition of hazardous waste
• Heating of the Plant
• Electricity
• Water
• Significant Aspects
• Use of electricity
• Use of water
• Monitor Measure
• Monthly bills
• Computer tracking
• Operational Controls
• IMPACC Energy Management System
• Communications
• Training

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Team Members

• Dave Wright - EHS Manager
• Scott Plemmons - Quality Assurance Mgr.
• Lana Plemmons - Training Coordinator
• Jim Takac - Facilities Manager
• Jim Rogers - Process Engineer
• Harold Brown - Powder Coating Operator
• Sam Godfrey - Maintenance Coach
• Rich Dunn - Mfg. Coach Controls

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Implementation Costs - Man Hours

• Dave Wright - 1,200 Hours
• Scott Plemmons - 680 Hours
• Remainder of the Team - 1,512 Hours
• Training Hours
• General Awareness - 1,200 Hours
• Significant Aspects - 160 Hours

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EATON - CUTLER-HAMMER ASHEVILLE PLANT
ISO 14001 REGISTERED