Recycling of Electrical Connector Caps at the Ford Michigan Truck Plant
Short summary:
Wiring harnesses are designed to be versatile. When a truck needs a particular feature, such as speed control, electrical connector caps on the wiring harness are removed, allowing the electrical connection ...
Long summary:
Recycling of Electrical Connector Caps at the Ford Michigan Truck Plant Ford Motor Company Pollution Prevention Case Study Recycling of Electrical Connector Caps at the Ford Michigan Truck Plant DESCRIPTION OF THE FACILITY The Ford Michigan Truck Plant is a 2.9 million square foot facility in Wayne, Michigan. The plant has been operating since 1964 and produces the Ford Expedition and Lincoln Navigator. It employs more than 4100 people and produced over 343,000 vehicles in 1997. DESCRIPTION OF THE OPPORTUNITY BEING ADDRESSED Wiring harnesses are designed to be versatile. When a truck needs a particular feature, such as speed control, electrical connector caps on the wiring harness are removed, allowing the electrical connection and adding the feature. Two electrical connector caps on wiring harnesses were being removed and discarded because they were not needed on many Expeditions and Navigators. A third cap was not needed on three-fourths of the trucks. DESCRIPTION OF THE IMPROVEMENT While the wiring harnesses were being re-designed, provisions were made for collecting and recycling the plastic caps. Plastic bins were made available for the formerly discarded caps. These caps, worth $56,000, were labeled and stored and were used for installation on the relatively few vehicles that needed them. Now, re-designed wiring harnesses arrive at the plant without caps, which saves at least $300,000 a year in parts and labor. SUBSTANCE ADDRESSED REDUCTION OBTAINED Plastic wiring caps 100% SAVINGS REALIZED (PARTS AND LABOR) $300,000 / YEAR ENVIRONMENTAL HIERARCHY LEVELS: Source reduction, waste stream elimination, and recycling.
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