Recently Ford released its 16th annual Sustainability Report highlighting its various ‘Green' achievements in Mexico's Hermosillo Stamping and Assembly Plant which attained zero waste-to-landfill status. Where do your Chennai and Sanand plants stand in this regard?
At Ford, sustainability is a business model that creates value, consistent with the long-term preservation and enhancement of environmental, social and financial capital. Ford facilities in Chennai and Sanand have implemented various green manufacturing practices, which reiterate the company's commitment to sustainability.
The Chennai Vehicle Assembly and Engine Plant for example is one of Ford's five zero-landfill facilities in the Asia Pacific region. The entire hazardous waste generated at the plant is either recycled or co-processed into allied cement industries, making this plant a zero-landfill facility. The Sanand plant will also adopt measures towards zero-landfill status.
What are some of the key ‘Green' manufacturing initiatives implemented by Ford India on the shopfloors of its Chennai and Sanand plants?
Ford India's Chennai plant has many notable manufacturing successes - we have achieved a reduction of 16 percent in terms of energy consumed per car produced since 2009.
Continuous improvement measures have also led to a reduction of 30 percent in terms of water consumed per car produced, while Volatile Organic Compound (VOC) emissions have reduced by close to 40 percent, over the same period. 100 percent of the wastewater is treated and reused within the facility, making this a zero liquid discharge facility.
Other notable green practices at the plant include emission control initiatives, cycle time reduction projects, reduction of waste in packaging material, switching over to LED lighting, regulating air conditioning systems, installation of solar heaters and effective use of sunlight in the factory floor.
Similarly, the Sanand plant redefines manufacturing excellence with its state-of-the-art modern equipment and advanced technology to deliver quality products. The state-of-the-art press shop, for example, will not only ensure that we produce the highest quality parts, but it will also maintain an exceptionally clean environment for employees with positive ventilation being deployed.
The Chennai plant implements the innovative three-wet paint process, which allows three coats of paint to be applied and dried simultaneously. This technology will be implemented at the Sanand plant as well. The energy efficient process significantly reduces wastage, energy consumption and helps in lowering paint shop carbon-dioxide emissions by up to 25 percent.
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