2015 Sustainability Report

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Waste

The more efficient we are in using materials to make our products, the less waste we produce, the fewer resources we consume and the more money we save. That is why we first work toward absolute material utilization throughout our manufacturing processes followed by reusing and recycling waste materials.
 
Following a successful pilot in 2014, we initiated a waste-mapping effort to track waste streams back to their source in our facilities worldwide. Each facility uses lean manufacturing methodologies to eliminate or minimize its waste one source at a time, typically starting with the highest-volume or highest-cost waste stream identified through the mapping process.
 
At the end of 2015, more than 50 percent of our facilities had mapped their waste streams. We anticipate that the remainder will complete the mapping process in 2016.
 
Our locations strive to achieve our global goals to reduce non-hazardous waste to landfill by 10 percent and hazardous waste to landfill by 20 percent by 2020 compared to our 2012 baseline. In 2015, the intensity of our non-hazardous waste to landfill (metric tons per 100 metric tons of production) declined 6 percent compared to the baseline, while our hazardous waste to landfill intensity increased 17 percent due to waste from a furnace rebuild. Without that furnace waste, our intensity would have remained unchanged from 2012.
 
We recycled 27 percent of non-hazardous waste and 48 percent of hazardous waste during 2015. 
 
We have started shifting our focus from waste sent to landfill to the total amount of waste we dispose of by landfill, incineration and treatment. This does not include waste that is recycled or reclaimed. In 2015, our total waste disposal intensity declined 3.8 percent from 2012 and 10.2 percent from 2014.
 
 

Waste Intensity
Metric tons of waste to landfill per 100 metric tons of production

 

Non-hazardous Waste

Hazardous Waste

2012
Baseline

3.29

0.06

2013

2.95

0.06

2014

3.30

0.06

2015

3.10

0.07

Recycled or Reclaimed Waste
Percent

 

Non-hazardous Waste

Hazardous Waste

2012
Baseline

15

32

2013

25

48

2014

23

45

2015

27

48

Remediation

Some of our past waste-disposal methods, which were legal and accepted industry practices in their time, can require environmental remediation or land reclamation to meet today’s regulations, our internal standards or stakeholder expectations.
 
We use a life cycle approach to assess and manage environmental issues and impacts at all of our facilities. A site assessment, which we require at various stages in a facility’s life cycle, provides an environmental evaluation according to standard industry practices. The assessment determines what, if any, remediation activities or restrictions will be implemented to meet our ultimate goal—each facility is in a condition in which it can be reused safely and productively.
 
Read about our specific remediation projects in our 2015 annual report.

Spills and Releases

Our facilities have strong management practices in place to prevent spills and releases. In 2015, we strengthened these practices even further through a new corporate spill-elimination standard that requires the establishment of a spill-elimination program at each facility.
 
The program consists of the following steps:
  • Assessment of a facility’s spill elimination performance;
  • Improvement plans based on prioritized assessment of risk;
  • Corrective action plan with defined dates; and
  • Completion of planned action.
 
We also continued to conduct spill-elimination workshops at various locations in 2015. During these events, a cross-section of location employees used a rapid improvement process and checklist to assess their facilities to identify areas for immediate improvement, as well as opportunities for longer-term action planning.
 
Moving forward, we plan to track our progress in this area with total spills and releases per 1,000 employees. On our path to eliminating spills, we aim to achieve an improvement of at least 10 percent per year in our spills and releases rate.

  
 
    
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