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GENERAL MOTORS ENVIRONMENTAL MANAGEMENT SYSTEMS Al Hildreth, Global Energy Manager May 29, 2014
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2 OVERVIEW OF GM MANUFACTURING Design, build and sell the world’s best vehicles Building 9 million vehicles per year= $1 billion in energy Enough electricity to power 1 million homes Carbon equivalent of 172 million trees for 10 years Enough water to fill 166 billion glasses or 30 million people per year
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GM ENVIRONMENTAL SUSTAINABILITY Supply Chain Product Manufacturing Vehicles GM has a commitment to the environment and sustainability that applies to every part of our business – from our supply chain, to product manufacturing, to the vehicles we put on the road. We’re continually assessing our environmental impact and taking steps to reduce it
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ENERGY & CARBON INTENSITY – 20% BY 2020 WE STRIVE TO REDUCE EMISSIONS AND PETROLEUM DEPENDENCE BY BEING MORE ENERGY EFFICIENT. Reduce Use Reduce Emissions Renewable Energy
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RENEWABLE ENERGY – 125 MW
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PRESERVE NATURAL RESOURCES GM GREEN WATERSHED EDUCATION 25 YEARS -
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WASTE REDUCTION – REDUCE, REUSE, RECYCLE
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COMMUNITY ENGAGEMENT
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GREENER VEHICLES – FUEL ECONOMY
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GM’S GLOBAL MANUFACTURING SYSTEM What – Goals & Objectives How - Methods When – Schedule and Control points Why – Vision & Mission Who – Responsible & Support Where – Focus on where value is added People Involvement 1. Vision, Mission5. Engagement 2. Health & Safety 6. Open Communication 3. Qualified People Process 4. Team Concept 7. Shop Floor Management Standardization 8. Workplace Organization 9. Management By Takt Time 10. Standardized Work Built-In Quality 11. Quality Standards15. Quality Management 12. Process & Product Validation System 13. In-Process Control & Verification 14. Quality Feedback/Feedforward Short Lead Time 16. Simple Process Flow 21. Scheduled Shipping / 17. Pull Systems Receiving 18. Lean Containerization 22. Temporary Material 19. Level Scheduling & Fixed Storage Period Orders 23. Supply Chain 20. Controlled External Management Transportation Continuous Improvement 24. Business Plan Deployment 27. Andon Concept/Process 25. Problem Solving28. Total Productive 26. Lean Design Maintenance 29. Continuous Improvement Process Each of the 5 GM-GMS Principles is supported by key elements. There are 29 GM-GMS Elements. GLOBAL MANUFACTURING SYSTEM MWh/Unit In GMS, E-Metric or Environmental / Energy is managed along with our Business Plan in “Continuous Improvement” Plan, Do, Check, Act aligns with Energy Star® guidelines
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GM’S GLOBAL ENERGY, CARBON, WATER INTENSITY GOALS 2010 – 2013 Performance Energy – 10% GHG – 7% Water – 9% Energy – 10% GHG – 7% Water – 9% 20% Energy 20% Carbon 15% Water
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ESTABLISH TEAM AND BUDGET INTEGRATE INTO BUSINESS MODEL Commitment from top leadership to integrate energy management into your business If energy spend is large enough, dedicated resources are needed Develop a dedicated budget to manage your energy business: People Utility expense Project expense /capital Commitment from top leadership to integrate energy management into your business If energy spend is large enough, dedicated resources are needed Develop a dedicated budget to manage your energy business: People Utility expense Project expense /capital GM Spend for Utilities = $1.1 Billion Company Energy Manager (4) Regional Teams (30) Site Utility Managers (120) 166 Sites in 30 Countries GM Spend for Utilities = $1.1 Billion Company Energy Manager (4) Regional Teams (30) Site Utility Managers (120) 166 Sites in 30 Countries NA SA EU IO $7M/person
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BENEFITS OF PARTNERSHIP WITH ENERGY STAR® BENCHMARK, NETWORK, RECOGNITION External Benchmarking Building – portfolio manager Vehicle assembly plants Machining plants (in process) Mechanism for internal benchmarking Supply chain effort (AIAG, SP) AIAG – Automotive Industry Action Group SP – Supplier Partnership environment 13
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EXTERNAL BENCHMARKING TOOL/RECOGNITION Standardized method Climate Building size Number of computers People Type of operations 14 ENERGY STAR ® PORTFOLIO MANAGER (6) GM Warehouses & offices labeled in US
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EXTERNAL BENCHMARKING TOOL/RECOGNITION Vehicle Assembly Plants Climate Vehicle size Air tempering Production utilization 15 ENERGY PERFORMANCE INDICATOR (EPI) (2) GM Assembly plants labeled in US
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BENEFITS OF PARTNERSHIP RECOGNITION External Recognition Best practice sharing Lessons learned Industry experts 16
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BENEFITS OF PARTNERSHIP RECOGNITION GM awarded: Energy Star ® Partner of the Year-Sustained Excellence 2013 & 2014 Energy Star ® Partner of the Year-Climate Communications Award 2014 8 Energy Star ® labeled facilities in U.S. Battle of Buildings 2013 (1) Top 10 for water (2) +20% for energy
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PRIORITIZE ASSEMBLY & PAINTING OPERATIONS Painting: 50% of energy & 70% water use PAINT OPERATIONS ARE 70% OF ASSEMBLY ENERGY Recycle air to automated zones Design in efficiency—fans, pumps 3 Wet paint process Automated shutdown Recycle air to automated zones Design in efficiency—fans, pumps 3 Wet paint process Automated shutdown
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ENERGY & CARBON FACILITY STRATEGY Reduction Energy Efficiency Conservation Fuel Switching Renewable Energy -125 MW -Hosting -PPAs Energy Efficiency / Conservation Design in efficiency – lean design engineering guidelines SME’s on new project teams LEED principles as guidance Dedicated budget for energy projects and Performance Contracting – $26 M or 5% Targets set for plants to meet public goals, ($ and MWh/vehicle) Sufficiency plans to meet target Hourly, daily dashboard Monthly scorecards Design in efficiency – lean design engineering guidelines SME’s on new project teams LEED principles as guidance Dedicated budget for energy projects and Performance Contracting – $26 M or 5% Targets set for plants to meet public goals, ($ and MWh/vehicle) Sufficiency plans to meet target Hourly, daily dashboard Monthly scorecards Steam elimination or reduction using direct fired gas Convert boilers to eliminate coal – Wentzville (52,000) tons CO2e Purchase steam – Hamtramck (57,000) tons CO2e, (35%) adds 16 MW renewable Steam elimination or reduction using direct fired gas Convert boilers to eliminate coal – Wentzville (52,000) tons CO2e Purchase steam – Hamtramck (57,000) tons CO2e, (35%) adds 16 MW renewable
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WHERE’S THE CARBON IN AUTOMOBILE LIFECYCLE? 10 year use of sold vehicle is majority (71%) of 327 million metric tons of CO2e Supply chain lifecycle for auto parts manufacturing is 2 nd at 23% Engagement with Supply Chain for carbon reduction is an important method to reduce vehicle lifecycle carbon CO2e KG /Vehicle GM = 880 Parts = 8,323 CO2e KG /Vehicle GM = 880 Parts = 8,323 Not including 232 M tons – use of vehicle – 10 years
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WATER USE IN AUTO MANUFACTURING Mexico Egypt S. Africa Kenya Australia China Water Stressed Countries – GM Manufacturing Water Stressed Countries – GM Manufacturing Water Efficiency and Conservation Strategy Design in water efficiency for new facilities Maximize reuse & recycle for new facilities in water stressed areas Implement retrofit projects to improve efficiency with positive business cases Integrate water conservation into business plan (monthly scorecard/metrics)
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QUESTIONS & ANSWERS 22
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