Automobile Sustainability Report

Executive Summary
In our report we discuss the various methods that today’s three major automakers are using to provide their customers with up to date, state of the art products. By implementing numerous breakthrough technologies into their production systems automakers are continuously working towards a more sustainable and environmentally friendly production process. Throughout our report we highlight major breakthroughs throughout the industry and how they have affected each individual company. By turning their attention to a more lean production process there have been many positive changes to help eliminate waste and reduce the cost of production. These companies are making conscious efforts to not only reduce the amount of waste produced throughout their systems but also how to reuse or recycle the waste that cannot be prevented. For example we talk about how Toyota has developed automated robotics systems to help control the amount of paint that is used during their topcoat operations to prevent the use of excess paint which is normally due to human error, another example is how they are using the paint sludge in the production of other products such as anti-rust paint sprays. We also discuss how the use of returnable metal shipping containers when shipping parts can greatly reduce the amount of wasted packaging materials and wooden creates from going to the landfills every year. All of these small changes have a large impact when looking at long term data analysis.

In today’s economy consumers as well as large scale corporations are always looking for new strategies to become more efficient with both their time and money. As consumers we are always looking for the best deal or something that is more efficient to save us a few dollars in the long run. For example to save a few bucks each year on our energy bills we have turned to power saving light bulbs, tankless water heaters and even extra insulation materials within our walls. The beauty of all of these changes that many people don’t realize is that they are all engineered ways of eliminating slack, better known as waste within our current ways of life. By eliminating the reservoir tank of the water heater we eliminate the use of excess gas used to keep the water warm even when we are not using it. These changes are not only saving us money but at the same time they are helping to preserve our natural resources which in turn is making our way of life more sustainable and environmentally friendly. As many of us may see the benefits of these small scale changes there are many corporations throughout the world that are also taking advantage of these ideas to help improve their own processes. A great example that we thought would be worth looking into is the automotive industry. There are millions of cars on the roads today and the production of vehicles is amongst the most competitive markets in today’s society. With the increasing gas prices and the slowing economy, the demands for more fuel efficient vehicles at lower pricing is out of control. In order for today’s big name players to stay in the game such as Toyota, General Motors as well as Ford motor company, they must develop new ways of producing their products and gaining the public’s attention and approval. If there is slack to be cleaned up in the energy use of a light bulb, than surly there are plenty of opportunities for these major manufacturers to clean up their processes as well. By making commitments to providing more environmentally green processes, more sustainable production techniques and reducing their carbon footprint these companies will gain respect from the public as well as fuel the fire of their competitors to do the same thing. When these events occur everybody prospers, consumers are provided with a cheaper more efficient product, corporations reduce the costs of production by eliminating unnecessary waste and our planet doesn’t suffer quite as much from the harmful effects of emissions. Within our report we discuss the steps and procedures that are being taken by these three big named players to do their part in creating a more efficient and environmentally friendly production system.

General Process of Vehicle Manufacturing

When vehicles are designed they generally take three to five years from inception to assembly. Designers develop ideas to respond to the public needs and preferences. The designers use computer programs to develop basic concept drawings that allow visualization of the product. From the computer drawing, clay models can be constructed and studied by styling experts that are familiar with the public wants and needs. Aerodynamic engineers also look at the models, studying air-flow parameters and doing crash tests. Once the models have been reviewed and accepted, designers are allowed to begin building the tools that will manufacture the components of the new vehicle model. The most of automobile raw materials consist of virgin steel and petroleum based products (plastics and vinyls). The light-weight materials formed from petroleum lighten vehicle models giving them increased fuel efficiency. The automobile assembly plants are the final phase in the manufacturing process. Components for vehicles are supplied by close to 4,000 outside suppliers. Parts are all delivered to the assembly plant and are brought to each of the different stations along the assembly line. The typical vehicle is constructed from the ground up. The frame of the vehicle forms the base that the body resides on. The frame is placed on the assembly line and locked into place to prevent shifting while moving through the line. The frame then moves to the component assembly areas where front and rear suspensions, gas tanks, rear axles and drive shafts, gear boxes, steering box components, wheel drums, and braking systems are installed. At this stage of the process an operation places the engine together with the transmission. The workers use robotic arms to install the heavy components. Once the transmission is installed a worker can attach the radiator. Heavy components are all placed in the vehicle using robotic arms and workers use pneumatic wrenches to bolt components into place. From here, floor pieces are welded together to the frame. The floor plan of the vehicle is the largest body component which includes multiple panels and braces that are welded or bolted to the vehicle. As the frame continues down the assembly line the shell of the vehicle is built. The left and right quarter panels are attached. The front and rear doors, roof, and body side panels are assembled next. Most of this work is done by robotic arms that can accomplish this work at a much faster pace than humans. Robots are preferred because of the ability to endure smoke, welding flashes, and gases created during the production phase. As the body moves from the isolated areas that only robotics work, the rest of the body components are installed. These components include fully assembled doors, deck lids, hood panels, fenders, trunk lid, and bumpers.
Once the body shell is complete, it is attached to an overhead conveyor for the painting process. The multi-step painting process includes inspection, cleaning, undercoat dipping, drying, topcoat spraying, and baking. Robotic arms once again help in this process and workers provide proper fit with pneumatically assisted tools. Before the painting process can begin the body of the car must go through a thorough inspection called the body white operation. The body goes through a white room that is brightly lit and is wiped down by inspectors with a hi-light oil. This oil allows the inspectors to see any defects on the cars frame. If there are any defects that need to be corrected skilled body repairmen make them on the spot. After the corrections have been made the body is then cleaned of all dirt, oil, and residue. Once the body is cleaned it goes through a drying station and is then painted with an undercoat called an E-coat. This coat is electrostatically charged and covers every square inch of the body. This is considered the primer coat, next up is there colored paint. Once the E-coat dries the final paint operation begins. The bodies of the vehicles are then spray-painted by robots. These robots have been programmed to apply precise amounts of paint on every inch of the car. This has taken a long time to perfect considering the first cars made were painted by hand with a brush. After the body has been fully painted and covered with a clear top coat it is moved into the baking ovens where the paint is cured at temperatures greater than 275 degrees Fahrenheit. Once the body is finished being painted the body of the car and the chassis frame are then bolted together. The car is then driven from the assembly line to a quality checkpoint. After the painting process is complete the interior of the car is ready for assembly. The painted body then goes through an assembly line where workers put together all of the wiring systems and instrumentation, dash panels, interior lights, seats, door and trim panels, headliners, radios, speakers, all of the glass except the windshield, steering column and wheel, body weatherstrips, vinyl tops, brake and gas pedals, carpeting, and the front and rear bumper fascias. Robots then insert the windshield into the bodies frame. After the car has gone through this assembly line it is given a water test to make sure the door panels, glass, and weather-stripping fit properly. Once this has been completed the body of the car is ready to be attached to the frame. The body is lifted robotically and placed onto the frame of the car. Assembly line workers then bolt the car body to the frame. The automobile then continues down the assembly line to receive the last components of its conception including a battery, tires, anti-freeze, and gasoline. After this final step is completed the car is then started and driven off of the assembly line to a checkpoint where the engine is audited, the lights and horn are checked, the tires are balanced, and the charging system is examined. If there are any imperfections found the vehicle is taken to a repair area where a group of skilled trouble-shooters examine and repair all problems. Once the car passes the final inspection it is given a price label and driven to a lot where it awaits to be shipped. Every one of the pieces that go into the production of an automobile is produced at another site. Most of these pieces will be constructed, tested, packaged, and shipped to the plants for use all in the same day. Mass amounts of planning go into this process. The automobile manufactures require the vendors to put their parts through scrupulous testing and inspections similar to the ones the used at the assembly plants. This was the plants can depend on the parts arriving at the on time and free from defects. Once the production of the automobile begins control specialists are able to track the production process of the vehicle by means of its Vehicle Identification Number, typically called the VIN number. In more advanced plants a small chip is placed in the chassis and floor pan containing all of the vehicles information. Being able to know what stages the vehicle has gone through, where it is going, and when it should arrive next gives the production management personnel complete control over the manufacturing process.

Toyota
Toyota Motor Corporation was founded in 1937 by a Japanese entrepreneur by the name of Kiichiro Toyoda who was the son of Toyoda Loom Works founder Sakichi Toyoda. Toyota Motor Corporation is headquartered in Toyota, Aichi, Japan and is the world’s largest automobile manufacturer by sales and production. Toyota sells its vehicles in over 170 different countries and does business with 51 overseas manufacturing companies in 26 different countries. Needless to say environmental greening and sustainability issues have a large impact on TMC. Since Toyota production plants are located all over the world they have recognized their obligations as far as respecting the atmosphere and developing highly sustainable and efficient means of production. “Toyota regards the protection of the global environment as one of its top priority concerns” According to Toyota Motor Manufacturing (UK). Toyota Motor Corporation’s commitment to the environment is shown through their development and focus on the full life cycle of their products, from design stages to production and even into disposal. By focusing on every aspect of the process many opportunities for improvement present themselves in each area. A few main areas that have captured the engineer’s attention are; waste reduction, 5R’s reduce, refine, reuse, recycle, recover energy, VOC reduction, continuous improvements as well as new product developments. In order for Toyota to achieve these targets they have developed and implemented various strategies and techniques. By consuming less natural resources and using more widely recycled materials in the production of their cars Toyota has drastically reduced their amount waste. Since 1999 Toyota’s North American production plants have reduced their landfill waste by a stunning 96%. By focusing on using recyclable materials such as olefin polymers used for Toyotas bumpers, dashboards and door trim the amount of wasted material can be significantly lowered. Olefin fibers are 100% recyclable synthetic fibers that are resistant to mildew, stains and sunlight and have good strength to be used for textiles, upholstery and vehicle interiors. Not only can production processes be improved but Toyota has also turned to its shipping sector to look for improvements as well. One innovative example that has saved the company money as well as prevented millions of pounds of waste was the implementation of metal returnable shipping containers used to ship parts and products around the world. Since being implemented in 2003 these containers have save 30 million pounds of wood, 10 million pounds of cardboard and more than $20 million in packaging costs. These savings were made because of Toyota believes in a long tern philosophy, which states that all management decisions should be based on long term philosophy, even at the expense of short term financial goals. Generating value for the customer, society and the economy is one of the main principles of Toyota. By achieving and sustaining an environmentally friendly product as well as process the company can continue to move forward. To show its dedication to the environment Toyota has developed an Environmental Management System (EMS) that has been approved by the International Organization for Standardization (ISO 14001). This organization helps corporations recognize how their operations negatively affect the environment as well as helps them reduce the impact in which they have on the environment. ISO 14001certification is essential in a high caliber corporation such as TMC. Being ISO 14001 certified means that Toyota must obey regulations, voluntarily invest in environmental projects, have plans to implement environmental projects, optimize resource utilization and supports all efforts to fulfill these expectations. A few examples of how Toyota has honored this policy are their efforts to reduce electricity consumption by installing more windows and skylights in their production plants to harness the use of natural light. All of the production plants industrial water pipes have been converted from galvanized steel to High Density Polyethylene (HDPE) pipe to help reduce water usage. By switching to HDPE pipes water can pass through the system with a lower resistance to flow because of the smooth inner surface, higher transmission capacity, and lower stress loss and water transmission consumption. Toyota has also developed ways to recycle other waste products such as paint sludge, used car oil, used parts, as well as reusing recycled materials as in dash insulators, floor silencers and deck boxes. Paint sludge is being recycled and reused as industrial anti-rust paint products and to help avoid excess paint waste computer programmed robots have been designed and developed to replace all humans in the painting area to establish a more efficient process. A process has also been developed and implemented to recycle the laminated glass products used for car windows and windshields saving 11,000 kg (24,250 lb.) of annual waste from reaching the landfill every year. Although finding ways to recycle and reuse waste products is a valued practice, the elimination of waste in general is a much better solution. When looking for ways to create an environmentally safe production process that is sustainable Toyota turned its focus to end of life vehicle (ELV). ELV incorporates the recycling and recovery rate of the vehicles produced as they reach the end of their usable life. By planning for this stage during the design process Toyota vehicles can be dismantled and recycled at much higher rates and efficiencies. For example when designing the 2005 Yaris Toyota implemented an easy to dismantle structural design which provides markings on all the vehicle components indicating where dismantling can best take place so no separating or sorting is required. Screw fasteners were replaced by clip fasteners, alignment markings were placed on bottom of the fuel tanks for safe removal of fuel during dismantling. Water based paints are now used for the top coat on the outer body panels to reduce emissions of volatile organic compounds (VOC). VOC’s are harmful to the environment because they react with oxides of nitrogen from combustion sources (the sun) to form ozone. This ozone that is formed is a smog like substance that reduces the quality of life and can affect humans as well as out atmosphere. These compounds are released into the atmosphere through exhaust stacks and usually are formed through painting operations. Besides reducing and eliminating waste Toyota must also focus on reducing the emission of CO2 along with other compounds that are equally as harmful to the environment. Co2 is the bi product of the combustion of fossil fuels, which is an activity that humans participate in to create energy. Co2 is the chemical formula for carbon dioxide, a harmful gas that contributes to the greenhouse effect as well as global warming issues. The greenhouse effect is defined as the process by which sunlight heats our planet and the heat energy that is trapped within our atmosphere that is related to the concentration of greenhouse gases. The more gases that are present means more and more heat is trapped, thus warming our planet. There are other greenhouse gases that add to this effect such as methane (CH4) and nitrous oxide (N2O) but are usually expressed as Co2 equivalents when being measured. Toyota has come to realize that they are a huge part of the problem when it comes to releases of these harmful gases and has been doing extensive research and project implementations to help reduce their carbon footprint. Since the main source of these harmful gases are from Toyota’s paints, solvents and afterburners they have implemented the use of articulated robots in the painting process to minimize the amount of paint required for each part. Along with the robots, air mixing valves are being used to reduce the amount of solvent required to clean the system. The formulation of the paints is undergoing improvements to help reduce the amount of odorous compounds as well as minimizing the amount of color changes in the topcoat area. The results of these changes have greatly reduced the emission of Co2 gases by approximately 340 tons per year. Based on the information I have obtained regarding Toyota’s current production processes I feel confident that they have already began taking the right steps towards self-improvement and environmental greening. After reviewing all of their concerns and changes that are being made throughout their production plants they certainly are heading in the right direction to help improve sustainability. By engineering new methods to help reduce their harmful emissions, reduce their amount of unnecessary waste and bi-products and implementation of automated robotics systems Toyota is already preparing for the future. As much as Toyota deserves a pat on the back for their efforts, in reality all of these changes and continuous improvement strategies are a must have in order for them to keep up with their competitors i.e. GM and Ford. In today’s economy consumers are always looking for the place that will provide them with the “most bang for their buck” and everybody knows that old technology and ways of doing business just won’t cut it anymore.

Ford

Ford Motor Company was founded on June 16, 1903 by Henry Ford. Their headquarters are in Dearborn, Michigan, where they make many different brand name vehicles. In the present day the two brand names they manufacture are Lincoln and Ford. Their innovation and creativity is what made them a dominant force in the world then and still till this day. They created a process known as the assemble line (Fordism) to create vehicles at a faster pace. They have the rank number five in the world in sales.

Ford has many different types of greening and sustainability issues that plague the company. The company uses a materiality analysis to determine what these issues are by asking the stakeholders of the company and also taking into account the issues of high strategic relevance to their company. The analysis performed by the company shows eight environmental-related issues including a low-carbon strategy, vehicle greenhouse gas emissions, fuel economy, cleaner technologies, public policy: greenhouse gas/fuel economy regulation, low-carbon fuels, vehicle electrification, emissions trading and the cost of carbon. The analysis shows a global theme of growing expectations in a wide range of issues related to their products and manufacturing facilities. The issues also affecting the company include energy and water use, tailpipe emissions, end-of-life management, and product materials use. The company lives by a thought process known as the precautionary principle. This principle states that if the consequences of an action are unknown, but thought of to have unfavorable outcomes, then you should not partake in the harmful actions. The company does not abide by this idea but attempts to apply this across the decision making of all the activities they participate in.

Ford has done the research on the issues that adversely affect the company. They have taken initiatives to clear up the problems at hand. The company is continually developing thorough strategies on a sustainable materials strategy. This is used to maximize the efficiency and widen the implementation of sustainable materials into the vehicles produced. The key aspect of the strategy is to recognize and globally implement materials to improve the environment and social operation, while lowering costs to the customers. Ford’s materials obtained for production must come from suppliers that are ISO 14001 certified. ISO 14001 is a part of ISO 14000, which are rules that are a series of guidelines set forth by the International Organization for Standardization. These guidelines are an environmental management standard that is used to help organizations minimize how their operations adversely affect the environment, comply with applicable laws and regulations, and continually improve all of these factors all the time. In 2006, Ford attained its goal of having 100% of facilities obtaining supplies from ISO 14001 certified vendors. Ford’s manufacturing management sets environmental targets annually for all facilities. They develop targets through comprehensive data of past performance, future regulation trends, environmental technology advances, financial conditions, and other relevant factors. Targets are set and the manufacturing plant that mets or exceeds these standards sets the bar for all other manufacturing plants. In 2005, Ford began to implement an Environmental Operating System (EOS) in North American assembly plants. This system drives compliance responsibility to the operations. This system also integrates ISO 14001. This system was integrated into all plants globally at the end of 2010. Ford’s Global Product Development System has environmental objectives. These objectives include targets for fuel economy, vehicle emissions, recycled and renewable materials, and restrictions on substances of concern. The company uses a range of consumer data, internal brand data and competitor vehicle data to determine customer demand targets. Ford is determined to introduce the best in class or among the best in class for fuel economy. Since 2009, they have followed through on this commitment. When designing vehicles, Ford uses a life-cycle approach to assess and minimize the total adverse impacts of the product. This thought process includes raw material extraction and transportation through manufacturing and use to the end of life. This is used to achieve a greater balance in the triple bottom line. The triple bottom line includes environment, social, and economic aspects. The company applies Design for Sustainability principles into their product lines. It helps to reduce the impacts of products over their life-time. Sustainable materials use is increased and undesirable materials are eliminated. Green house gases and other harmful emissions have been reduced by developing cleaner production processes. They also look at improving the efficiency of packaging and transportation logistics and introducing cleaner and more fuel-efficient vehicles. During the process of making a vehicle the facilities release emissions and Ford is focused on reduction and elimination of emissions. A significant emission during the production phase is volatile organic compounds (VOCs). Ford has cut these emissions by more than 30% since 2000. The main cause of this is Ford’s innovative “fumes-to-fuel” system. The system uses concentrated fumes containing VOC emission from the solvent-based paint as fuel to generate electricity. The process starts with a concentrator that strips air from paint fumes, leaving concentrated VOCs. Next, a reformer process converts the VOCs to hydrogen gas. The final step involves the generator which uses the hydrogen gas as fuel for fuel cells or conventional power plant to make electricity. Ford is actively involved with finding more energy efficient ways to run facilities. This is done through wind turbines, hydro-electric, and solar applications. To be more environmental friendly, Ford has goals of reducing the amount and toxicity of manufacturing-related wastes that will ultimately lead to the elimination of disposal in landfills. Ford targets hazardous waste first because of the quickness and cost benefits to human and environmental health. There are seven facilities of Ford that achieved zero waste in landfills and will continue to turn the rest of the facilities into zero waste operations. Another initiative that Ford introduced was a water-reduction operation. The company developed a patented Water Estimation Tool (WET), that helps track and predict water usage. They pair this program with another idea Water Ideas to Lessen Demand (WILD). This is a list of ideas to reduce water use depending on where and when use is the greatest. The facilities have implemented this procedure and continually meet the goal of a 3% water reduction annually year to year. Ford has put a living green roof on top of their Ford Truck Plant in Dearborn, Michigan. This will heat and cool the building and increase productivity of the workers. Also, it will save a lot of money in the long run. It was design by William McDonough. He met with Bill Ford and they decided to put up a 10.4 acre living roof on top of the plant. Not only did this give them their heating/cooling, but helped with runoff, and helped create cleaner air around the plant. In addition to the living roof they planted thousands of trees and shrubs around the plant which not only made it environmentally healthier, but socially more accepted. The biggest effect it had was the effect on the Rouge River which was being damaged by the runoff of the plant. Now with this new plant there is little to zero runoff and slowly restoring this river. The debate to shut down this particular plant is now officially done. It set the bar higher for other organizations to follow. If a building this large can do it, any building can do it. The future of Ford involves the continued use of hybrid technologies and deployment of alternative energy sources. The increased percentage of engines using renewable fuels is a top priority. The introduction of plug-in hybrids and battery electric vehicles will become more and more widely available. The future of the automobile is really held in fuel cell technology and hydrogen fuel. The company will continue to strive for environmental progress and create a cleaner world for the future generations to come. The Ford Motor Company has taken steps in the right direction to further their involvement and success in the environmental sustainability area. They continually meet or exceed the expectation targets of sustainability. Looking into the future, Ford has nowhere to go but up. This is a transition period from conventional vehicles to more sustainable vehicles. The future is now and everyone must play their part to ensure a safe environment for everyone.

General Motors
General Motors was in September of 1908 in Flint, Michigan by William C. Durant as a holding company for Buick. Before General Motors was founded the company was called the Durant-Dort Carriage Company and had been in business since 1886 and was producing over 100,00 carriages a year by 1900. Over the next couple of years Durant went on to acquire several different name brand automobile companies including both Cadillac and Pontiac and also co-founded the Chevrolet Motor Company. Toady GM is the second largest car manufacture based on annual sales in the world and provides jobs to roughly 266,000 people worldwide. General Motors manufactures automobiles in 35 countries and is continually growing and expanding in the ever changing automobile industry. Today GM has made environmental sustainability a main focus at its facilities around the world. Despite some setbacks in the past GM has worked hard to move past them and reduce its environmental impact by implying several different sustainable manufacturing practices. Mass air pollution and toxic dumping is no stranger to the automobile industry. Over the past decade General Motors has been cited for mass air pollution and dumping on several occasions. One of the first came in 2002 when the EPA cited not only GM but also Ford as two of the top 100 corporate air polluters. Then in March of 2006 GM was ranked as the 20th worst polluter in the world.
General Motors affects the environment in many different ways. Two of the main ways are being a huge automobile factory that produces hundreds upon thousands of pounds of air pollution every year, the second way is the main purpose of the corporation and that purpose is being able to produce oil and gas guzzling automobiles at a rate of 60 cars per hour. General Motors has also had problems with adding sufficient amounts of waste to landfills causing even more problems for our environment.
Since being cited multiple times by the EPA and facing several multi-million dollar law suits GM has made noticeable strides in the right direction. General Motors has adopted several environmental principles which serve as a guideline to their employees. These guidelines help them become more environmentally conscious not only while working but also in their daily lives. These principles will also help in the planning of future products.
While the average person only thinks about the automobile that this company is producing and how environmentally friendly it is GM is trying to draw the attention in the direction of the manufacturing line as well. They want the public to know that the operation they are running is not only sustainable but environmentally friendly and that the conservational impact of the vehicle being produced has been thought of during this process. GM has made significant improvements in cleaning up and reducing factory emissions, conserving resources, and eliminating waste. In the manufacturing division GM is one of the leading users of renewable energy. They have learned to harness the power of natural energy by using solar and hydro power. GM has also invested in waste based energy, this being the use of landfill gas. The use of landfill gas replaces the use of natural gas. General Motors has implemented this into several facilities across the nation. Landfill gas is a fuel that burns clean and fits as a flawless replacement for the manufacturing plants boilers. By using these renewable resources GM has not only been able to save energy but also reduce emissions.
Aside from harnessing energy from landfills GM is implementing landfill-free practices into more and more of its facilities. This means that waste generated from the facilities operations is converted to energy, reused, or recycled, the company currently has 76 landfill-free facilities. This is just one of many efforts being taken to reduce their environmental impact. Waste management is a big part of this company and GM is making it a point to implement new ways of reducing and reusing waste. The first step taken is working toward reducing the amount of wasted generated then recycle the waste that is unavoidable. Over the past year GM has been able to recycle and reuse 2.5 million tons of waste generated at its facilities around the world. Monitoring the monthly waste generated is one thing that helps them work towards these goals. By monitoring the waste generated each month they are able to tell which materials are being reused and recycled and in which areas they need to work on improving. The landfill-free plants on average recycle and reuse 97 percent of the waste generated leaving the other 3 percent to be converted to energy and waste-to-energy facilities. One of the critical steps in the landfill-free process is taking material byproducts from the everyday manufacturing process and turning them into components for new vehicles. For example GM took the cardboard used to ship their products and turned it into sound-absorbing material put in the headliner of the Buick Lacrosse. Other plastic shipping aids have been turned into radiator shrouds for the Chevrolet Silverado and GMC Sierra pickup trucks. The tires used during vehicle testing are also recycled; they are shredded and used in the production of air and water baffles for an array of different GM vehicles. And lastly paint sludge that is leftover from painting the automobiles is turned into a plastic material that is used to ship the car engines they manufacture. All of GM’s facilities worldwide collectively recycle 90 percent of the waste the produced. Since GM has made noticeable strides in area of waste reduction has been introduced into the U.S. EPA WasteWise Hall of Fame and to this date is the only auto manufacturer to do so. By using renewable energy GM has not only been able to save energy but also has been able to reduce the amount of CO2 emissions produced by its facilities.
When manufacturing their vehicles it is the engineers and designers job to find new ways to advance the impact the products will have on the environment from beginning to end. While a new vehicle is being designed GM tires to use bio-based and recycled materials whenever possible. This is an ongoing process that both engineers and suppliers must to work on to increase the use of these recycled materials in the product. These recycled materials come from a variety of different sources. These include old pop bottles, blue jeans, nylon carpet, used tires, and recycled vehicle bumpers. GM is also currently looking for ways to reuse their waste products from manufacturing facilities for parts used in new vehicles being produced. If GM is able to implement this practice it will allow a closed loop process which converts waste that would regularly go to a landfill to use as a part of a new product. Another step being taken to make their cars and trucks more sustainable is the use of renewable natural fibers in vehicle parts. After a car has reached its end life GM works to make sure that whatever happens to those vehicles has a positive impact on the environment. A big part of their vehicle development is designing them to be as recyclable and recoverable as humanly possible. There are ISO standards set in place on vehicle recycling and recoverability and GM not only follows them but also implements internal global standards to make beneficial gains across the region. To date GM’s vehicles are no less than 85 percent recyclable and 95 percent recoverable and make it a point to work directly with the vehicle dismantling industry to ensure that the majority of the material can be recycled and reused in new vehicles and products.
General Motors has been doing extensive research on hydrogen fuel cells. They recently developed the Chevrolet Equinox which is a fuel cell electric car that runs on electricity produced by an on-board fuel cell stack. The only emission this vehicle produces is a wisp of water vapor. Instead of filling this car up with gasoline it is filled with about 4.2 kilograms of compressed hydrogen about. This is enough to take you 168 miles before a 7 minute refill is needed. When the car breaks it sends the energy created back to the battery which extends the driving range. However the mass production of these vehicles has been hindered due to the high cost of development and lack of fueling stations. Aside from the fuel cell General Motors has been looking to other alternate options for gasoline in the biofuel area. They currently offer 19 different models that can run on E85. E85 is a blend of both ethanol and gasoline, the use of this blend helps reduce the dependence on petroleum and provide the consumer with an alternate option. Despite not being able to mass produce the fuel cell GM has taken imitative in the area of fuel economy. They now have 12 different models which can reach 30 miles per gallon on the highway and five different types of hybrid vehicles. GM has been able to produce more efficient vehicles by applying the use of several different technologies such as six speed transmissions, Active Fuel Management, variable valve timing, and direct injection.
General Motors as a whole has made very sufficient progress in the area of becoming a sustainable company. They have implemented new ways of reusing and recycling their waste products as well as turning them into energy. Despite the problems they’ve had in the past they have done a very good job of correcting their errors and working past them. Over the past decade GM have proven that they care about the environment and the impact they have on it.

Toyota Works Cited

"About Us - Environment." Web. 3 Apr. 2011. <http://www.toyotauk.com/main/about-us/Environment.jsp>.

"Environmental Efficiency throughout the Production Process." Welcome to Toyota Europe Portal Page. Select Your Country. Web. 3 Apr. 2011. <http://www.toyota-europe.com/corporate/environment/360-approach/making-the-car.aspx>.

"Environmental Programs." Toyota Cars, Trucks, SUVs & Accessories. Web. 3 Apr. 2011. <http://www.toyota.com/about/philanthropy/environment/>.

"Greener Manufacturing." Toyota Cars, Trucks, SUVs & Accessories. Web. 3 Apr. 2011. <http://www.toyota.com/about/environment/operations/green_manufacturing.html>.

"Greener Operations." Toyota Cars, Trucks, SUVs & Accessories. Web. 3 Apr. 2011. <http://www.toyota.com/about/environment/operations/green_operations.html>.

Http://www.wikinvest.com/stock/Toyota_Motor_(TM)/Components%20Parts%20Raw%20Materials%20Sources%20Supply. Web. 3 Mar. 2011.

"Toyota Environment: Vehicle Lifecycle: Manufacturing." New Cars from Toyota Australia: New Car Prices: Dealers: Brochures & Book at Test Drive. Web. 1 Apr. 2011.
<http://www.toyota.com.au/toyota/events/environment/manufacturing>.

Web. 3 Mar. 2011. <http://web.mit.edu/2.810/www/lecture09/14.pdf>.

"Worldwide Operations." TOYOTA MOTOR CORPORATION GLOBAL WEBSITE. Web. 3 Apr. 2011. <http://www.toyota-global.com/company/profile/facilities/worldwide_operations.html>.

Ford Works Cited
"Design for Life-Cycle Sustainability - Sustainability Report 2009/10 - Ford." Ford Motor Company – Official Global Ford Corporation Information. Web. 26 Mar. 2011. <http://corporate.ford.com/microsites/sustainability-report-2009-10/environment-lifecycle>.
"Environment - Sustainability Report 2009/10 - Ford." Ford Motor Company – Official Global Ford Corporation Information. Web. 26 Mar. 2011. <http://corporate.ford.com/microsites/sustainability-report-2009-10/environment>.
"Facilities-Related Emissions - Sustainability Report 2009/10 - Ford." Ford Motor Company – Official Global Ford Corporation Information. Web. 26 Mar. 2011. <http://corporate.ford.com/microsites/sustainability-report-2009-10/environment-operations-facilities>.
"Ford Overhauls Factory to Be Green - US News - Environment - Green Machines - Msnbc.com." Breaking News, Science and Tech News, World News, US News, Local News- Msnbc.com. Web. 26 Mar. 2011. <http://www.msnbc.msn.com/id/4843708/ns/us_news-environment/>.
"How Automobile Is Made - Production Process, Manufacture, Making, Used, Parts, Components, Product, Industry, Raw Materials, Design, The Manufacturing Process of Automobile." How Products Are Made. Web. 26 Apr. 2011. <http://www.madehow.com/Volume-1/Automobile.html>.
"Operational Energy Use and Greenhouse Gas Emissions - Sustainability Report 2009/10 - Ford." Ford Motor Company – Official Global Ford Corporation Information. Web. 26 Mar. 2011. <http://corporate.ford.com/microsites/sustainability-report-2009-10/environment-operations-energy>.
"Operations - Sustainability Report 2009/10 - Ford." Ford Motor Company – Official Global Ford Corporation Information. Web. 26 Mar. 2011. <http://corporate.ford.com/microsites/sustainability-report-2009-10/environment-operations>.
"Renewable Energy Use - Sustainability Report 2009/10 - Ford." Ford Motor Company – Official Global Ford Corporation Information. Web. 19 Mar. 2011. <http://corporate.ford.com/microsites/sustainability-report-2009-10/environment-operations-energy-renewable>.
"Water Use - Sustainability Report 2009/10 - Ford." Ford Motor Company – Official Global Ford Corporation Information. Web. 26 Mar. 2011. <http://corporate.ford.com/microsites/sustainability-report-2009-10/environment-operations-water>.

General Motors Works Cited
"Consumer Reports' 2010 Annual Car Reliability Survey: GM makes big strides, while Honda, Toyota dominate." Consumer Reports News. N.p., n.d. Web. 12 Apr. 2011. <http://news.consumerreports.org/cars/2010/10/consumer-reports-2010-annual-car-reliability-survey-gm-makes-big-strides-while-honda-toyota-dominate-pr.html>.
"GM - Environment - Environmental Principles - English." General Motors | GM.com. N.p., n.d. Web. 10 Apr. 2011. <http://www.gm.com/corporate/responsibility/environment/principles/index.jsp>.
"GM - Green Materials and Vehicle Recycling." General Motors | GM.com. N.p., n.d. Web. 22 Apr. 2011. <http://www.gm.com/corporate/responsibility/environment/recycling/index.jsp>.
"GM - Greener Vehicles." General Motors | GM.com. N.p., n.d. Web. 20 Apr. 2011. <http://www.gm.com/corporate/responsibility/environment/greener_vehicles/index.jsp>.
"GM - Sustainable Manufacturing ." General Motors | GM.com. N.p., n.d. Web. 15 Apr. 2011. <http://www.gm.com/corporate/responsibility/environment/facilities/index.jsp>.
"GM - Sustainable Manufacturing ." General Motors | GM.com. N.p., n.d. Web. 19 Apr. 2011. <http://www.gm.com/corporate/responsibility/environment/facilities/index.jsp>.
"We rate General Motors: What's good, what's bad, what's next." Consumer Reports: Expert product reviews and product Ratings from our test labs. N.p., n.d. Web. 11 Apr. 2011. <http://www.consumerreports.org/cro/cars/new-cars/resource-center/automakers-bailout/general-motors/automaker-bailout-general-motors.htm>.
Westfall, Mike . "The Cutting Edge News." The Cutting Edge News - Page One. N.p., n.d. Web. 2 Apr. 2011. <http://www.thecuttingedgenews.com/index.php?article=11287>.