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This is the second feature in a series highlighting Delphi's commitment to protecting the environment through safe, green, and connected technologies and initiatives.
Green processes. Green products. Green-conscious people. At Delphi, being "green" is more than a management philosophy it's a way of living and it shows. At every level and in every process, Delphi takes its role as environmental steward seriously.
As an industry leader in supporting environmental issues, Delphi works to minimize environmental impact and reduce its global footprint through finely tuned, efficient manufacturing operations. By developing energy-efficient products that require fewer resources and that offer increased recyclability and lower emissions, Delphi helps customers get serious about protecting natural resources, too.
Environmental stewardship is key at Delphi's global manufacturing operations, where continuous improvement of the plants' environmental operations is a primary focus. From updating and streamlining production processes on the plant floor to recycling resources in an office, Delphi employees around the world are dedicated to protecting natural resources.
Energy-Efficient European Operations Shine
In 2010, 38 Delphi manufacturing facilities in Europe and Morocco participated in the hugely successful CO2 Emissions Reduction Program, saving more than 7,716 tons (7,000 tonnes) of CO2 and exceeding their goal by more than 50 percent.
The "green" program began in 2008 as a way to proactively minimize the environmental impact of manufacturing processes, products, and technologies. Since then, Delphi plants have avoided more than 16,500 metric tonnes of CO2 emissions savings equal to the carbon footprint of about 550 families of four living in a medium-sized home in Europe.
One key to the success of the program is the Climate Change Toolbox, an inventory to help employees reduce CO2 emissions on the job and at home. Linking with Delphi's global efforts to define and reduce its carbon footprint, the program offers employees tips and initiatives to increase environmental awareness and save energy.
Read more about environmental initiatives at Delphi plants in Europe and Morocco.
Delphi Plants Take up the Green Challenge
Also in other regions of the world, Delphi facilities are developing new programs and making operational changes to conserve energy and materials, reduce emissions, and promote responsible recycling. Plant managers are encouraged to share successes in reducing environmental and energy impacts of products and manufacturing processes with the public and customers. These projects help Delphi identify and share "best practices," which may be effectively used in other facilities.
Water Use Reduced in Wuhan, China
Aware of the need to reduce manufacturing's impact on natural resources, management at the Delphi Packard Electrical/Electronic Architecture (E/EA) plant in Wuhan, took steps to reduce water use throughout the plant. In plant restrooms, new water-saving faucets were installed and toilet-tank water levels were reduced. With the design and implementation of a water-leak inspection schedule and reporting system, total water use in the plant decreased by 29 percent in 2010.
Water Purification Advances for Seoul, South Korea
Plant leaders at the Delphi Technical Center in Seoul, recently received government authorization to conduct on-site oil skimming, eliminating the need for a third-party water treatment provider and associated discharge fees. By committing to the safe, efficient processing and discharge of wastewater from manufacturing, Delphi is reducing its impact on the environment with a real-world solution.
Shanghai, China Upgrades Equipment
Several projects developed at the Packard E/EA Shanghai A5 plant in 2010 provided cost-savings and helped Delphi reduce environmental impact. The addition of a transducer to improve efficiency of the air compressor system contributed to an 18.5 percent energy cost savings and decreased annual CO2 emissions by more than 138 tons.
Lighting efficiency improvements in the plant are also helping to reduce environmental impact and increase energy savings. Electric street lamps on plant properties were replaced with solar- and wind-powered fixtures, reducing CO2 emissions by 4.64 tons last year.
Redesigning the alarm lamp system on an advanced automated machine used in production of wire harnesses permits the use of energy-efficient LED bulbs, extending maintenance-free time to more than 10,000 hours and decreasing annual CO2 emissions by more than 17.26 tons.
Creative Changes for Shanghai
At the Delphi Packard E/EA Shanghai Plant, replacement of the compressed air system led to significant and noticeable improvements in the plant operations. The new vacuum pump system, running only 16 minutes per day, dramatically reduced electricity use, resulting in energy cost savings of 2.2 million kWh in 2010. The equipment upgrade also reduced particulates in the air and lowered noise levels in the plant by 13 dB.
Greening Up Building Systems in Flint, Michigan, USA
At Delphi's plant in Flint, consolidating electrical loads to a single transformer in a double-ended substation reduced the plant's energy consumption by 6 percent over the first 10 months of operation. By running the transformers at peak efficiency, the plant operations realized over 10 percent energy cost savings during the first year.
Improvements to the building heating system also resulted in cost and energy savings at the site. The addition of two direct-fired gas air heaters led to a 35 percent reduction in carbon emissions during the first two months of operation. Additionally, the conversion from steam heat to direct-fired gas heat resulted in reduced water usage, treatment costs, and boiler maintenance costs.
Eco-Efficiency in Juarez, Mexico
At Delphi RBE (Rio Bravo Eléctricos) I in Juarez, plant management took a "big picture" look at eco-efficiency and improved value stream productivity and competitiveness. By focusing on a commitment to dependable, efficient processes, they made cost-saving equipment and maintenance changes including:
While saving operational costs, these projects made a positive impact on the environment, reducing annual CO2 emissions by 830 tons, metal waste by 20,250 kg, plastic waste by 18,275 kg, and energy use by 1,269,209 kWh.
Energy-Savers in Brookhaven, Mississippi, USA
At Delphi's Packard E/EA plant in Brookhaven, modification of the building air handling system and an equipment upgrade helped save energy and reduce the impact on natural resources. With funding from the U.S. Department of Energy, efficiency improvements through the replacement and relocation of condenser equipment resulted in a reduction of the plant's energy use by 1,642,857 kWh in 2010 in addition to a decrease in their carbon emissions. Additional improvements planned for 2011 are expected to add to energy savings at the plant.
Living Green A Full-Time Job
Delphi employees understand that commitment to the environment extends beyond manufacturing processes and products. Routine office duties, as well as personal activities, offer opportunities to demonstrate a green commitment. At Delphi plants around the world, employees participate in workplace environmental initiatives as a way to be personally involved in the green movement while supporting the local community.
Making a Difference in Shanghai
Increasing environmental awareness and making a local impact was the goal of volunteer projects recently led by employees at the Delphi Packard E/EA Shanghai A5 plant in China. Employees demonstrated their commitment to the environment by participating in a variety of projects from clean-up efforts to educational programs:
Forest Preservation in Wuhan
Employees at the Delphi Packard E/EA plant in Wuhan, China, led more than 500 volunteers and 10 area businesses in a tree planting effort near the plant. Their commitment to saving paper and encouraging forestation increased environmental awareness among Delphi employees and the local community while beautifying the environment.
Celebrate the Earth in Singapore
Employees taking part in environmental activities at the Delphi Singapore operations in China learned valuable personal lessons on how to reduce environmental impact. Employee volunteers at the plant promoted environmental awareness through a variety of activities:
Throughout Delphi's U.S. operations, resource-saving measures are being conducted to reduce waste and save energy including:
At Delphi, the continuous improvement of environmental performance begins with the employees. Protecting human health, natural resources, and the environment in which we live is a commitment Delphi and its employees take seriously. This commitment to focusing on the future goes beyond today's definition of "green."
As an industry leader in sustainable manufacturing and sustainable products, Delphi creates real-world innovations while helping customers reduce their impact on the environment. Learn more at delphi.com.
Learn more about Delphi's "green" innovations and initiatives by reading about our recent honors.