ISO/TS 16949-2002 ISO 14001

The Electroplating Sector: Compliance Assistance, Enforcement, and Pollution

Prevention

ISO/TS 16949-2002 ISO 14001

Elizabethtown, KY USA

COMPANY COMPANY OVERVIEWOVERVIEW

ISO/TS 16949-2002 ISO 14001

Location: Elizabethtown, Kentucky Ownership: 100% Akebono Brake Corporation Incorporated: July 18, 1986 SOP: May 1988 (GM, HONDA)

Land Size: 55 Acres Building Size: 348,000 SQ FT

Associates: 1,157 Total [ January 2007)

Work Schedule: 3 Shift/5 Day, Weekend Crews (3d/12 hr)

OUTLINE

““

ISO/TS 16949-2002 ISO 14001

AKEBONO BRAKE CORPORATION North American Facilities

• AKEBONO BRAKE – ELIZABETHTOWN PLANT, KY (1988)

• AKEBONO BRAKE – GLASGOW PLANT, KY (1994)

• AKEBONO ENGINEERING CENTER, MI (1998)

• AKEBONO BRAKE – SPRINGFIELD PLANT, KY (2001)

AKEBONO ENGINEERING

CENTER

AKEBONO BRAKE – ELIZABETHTOWN

PLANT

AKEBONO BRAKE –

SPRINGFIELD PLANT

AKEBONO BRAKE –

GLASGOW PLANT

ISO/TS 16949-2002 ISO 14001

DAILY PRODUCTION VOLUMES(BASED ON 2006 AVG.)

FRONT & REAR CAST IRON FRONT & REAR CAST IRON CALIPERS

27,500/27,500/DAYDAY

REAR INTEGRAL REAR INTEGRAL CCALIPERS

2,500/2,500/DAYDAY

REAR ALUMINUM REAR ALUMINUM CCALIPERS

3,500/3,500/DAYDAY

REAR DRUM REAR DRUM BRAKESBRAKES

11,000/11,000/DAYDAY

PAD PAD ASSEMBLIESASSEMBLIES

55,000/55,000/DAYDAY

ISO/TS 16949-2002 ISO 14001

PRODUCTSFRONT & REAR CAST IRON FRONT & REAR CAST IRON

CALIPERSCALIPERS

(SINGLE & DUAL PISTON)(SINGLE & DUAL PISTON)

REAR INTEGRAL & ALUMINUM REAR INTEGRAL & ALUMINUM CALIPERSCALIPERS

(SINGLE & DUAL PISTON)(SINGLE & DUAL PISTON)

REAR DRUM BRAKES REAR DRUM BRAKES

(DUO-SERVO & PARKING)(DUO-SERVO & PARKING)

FRONT & REAR PAD FRONT & REAR PAD ASSEMBLIES ASSEMBLIES

NAO - (NON-ASBESTOS NAO - (NON-ASBESTOS ORGANIC)ORGANIC)

ISO/TS 16949-2002 ISO 14001

CUSTOMER BASE - DOMESTICS

Solstice (Ft Caliper)

Malibu (Ft/Rr Caliper/Pad)

G6 (Ft/Rr Caliper/Pad)

Cobalt(Ft Caliper/Pad)

Saturn Ion(Ft Caliper/Pad)

Opel GT (Ft Caliper)

Saturn Sky (Ft Caliper)

Chevy Impala (Rr Caliper/Pad)

HRR (Ft Caliper/Pad)Grand Prix (Rr Caliper/Pad)

Cadillac DTS (Rr Caliper)

Rendezvous (Rr Caliper/Pad)

Monte Carlo (Rr Caliper/Pad)

Saturn Red Line (Fr Caliper/Pad)

Pontiac Pursuit (Fr Caliper/Pad)

Lacrosse (Rr Caliper/Pad)

LeSabre (Rr Caliper)

ISO/TS 16949-2002 ISO 14001

CUSTOMER BASE - DOMESTICS

Buick Terraza (Rr Caliper)

Chevy Trailblazer (Rr Pad)Chevy Uplander (Rr Caliper)

Saturn Relay (Rr Caliper)

Pontiac Montanna (Rr Caliper)

Envoy (Rr Pad)

Chevy Tahoe (Rr Caliper/Pad)

Suburban (Rr Caliper/Pad)

Chevy Express (Rr Caliper/Pad)

Chevy Savanna (Rr Caliper/ Pad)

Ford Econoline (PKB)

ISO/TS 16949-2002 ISO 14001

CUSTOMER BASE - TRANSPLANTSToyota/Toyota/

NUMMINUMMIHONDAHONDA MITSUBISHIMITSUBISHI

Civic (Ft Calipers/Pads)

Accord (Ft Calipers/Pads)

Acura TL (Ft Pads)

MDX (Rr Caliper/Pads & PKB)

Pilot (100%)

Ridgeline (Ft Caliper/Pads, Rr Pads & PKB)

Element (Ft Calipers/Pads)

Corolla (100%)

Avalon (Rr Caliper)

Solara (Rr Caliper)

Matrix (Ft Caliper, Drum Brake)

Vibe (Ft Caliper, Drum Brake)

Eclipse / Spyder (100%)

Galant (100%)

Endeavor (PKB)

Tundra (Rr Caliper)

ISO/TS 16949-2002 ISO 14001

Mix & Blend

DA82

DA81

DA80

ED

P

BP70

BP71

BP72

BP73Pist

on

Mac

hini

ng

SL62

SL61

SL60

SL

63 /

64

AD

66

/ 67

US50 US52

US51 US53 Pho

spha

tor

E-

Nic

kel P

latt

er

Pist

on

Fini

shin

g

Pist

on

Mac

hini

ng

DM

3D

M2

DA3

DA2

Dis

c

Mai

nten

ance

/ Sto

re

DM

1

DA1G

ener

al

Sto

re

DM

8

DM

9

DM

10

DM

11

DM

12

DM

13Pl

atte

rDA13

DA12

DA11

DA10

DA9

DA8

Piston sub-assembly

DM

4D

M5

DM

7D

M6 DA4

DA5

DA7

DA6

Shipping & Receiving Docks

MP1

FB2

FB1

FB3

CO

3C

O2

HP

4

HP

5H

P6

HP

7

ST1

CO

1

HP3

HP2

HP1

ST2

CO

5

CO

4

HP

8

HP

9

Orbit-form

Kai

zen

Are

a

Quality Assurance

Disc Office

Front OfficeCAFETERIA

1

Fric

tion

Off

ice

Drum Office

Friction QC Office

Die Maintenance

DA14

Shim/Bond

HP

10

CO

5

Paint

Paint

Gri

nder

/Sco

rche

rG

rind

er/S

corc

her

MD

C

DM

14

DM

15

DM

16

DM

17

DA

15

SER

VIC

E

PDA

CA

FET

ER

EIA

/APS

Disc Brake Drum Brake/Piston Friction

PLANT LAYOUTAluminum

ISO/TS 16949-2002 ISO 14001

WATER CONSERVATION

Conductivity Flow Control of Rinse Water Volume

Counter Current Rinse Tanks on Metal Finishing Lines

Flow Restriction Devices on Individual Rinse Tanks

ISO/TS 16949-2002 ISO 14001

Conductivity Flow Control of Process Rinse Water

ISO/TS 16949-2002 ISO 14001

Conductivity Meter

ISO/TS 16949-2002 ISO 14001

Calibration of Conductivity Meter

ISO/TS 16949-2002 ISO 14001

First Stage Rinse Tank

ISO/TS 16949-2002 ISO 14001

Final Stage Rinse Tank

ISO/TS 16949-2002 ISO 14001

Two Stage Conductivity Controlled Rinse Tanks

ISO/TS 16949-2002 ISO 14001

CONDUCTIVITY FLOW CONTROL OF RINSE WATER VOLUME

Flow Control Based on Conductivity of First Stage Rinse Tank of Counter Current

Application

Conductivity Set Point Determined by Analysis of Rinse Water and its Effect on Painting Quality

Rinse Water Reduced in Painting Operation From 7,000 gpd to 2,500 gpd

ISO/TS 16949-2002 ISO 14001

Two Stage Counter Flow Rinse

ISO/TS 16949-2002 ISO 14001

KPPC ENERGY EFFICIENCY ASSESSMENT REPORT

• Major Energy Consuming Equipment: >10 h.p.• Energy Bill Analysis• Energy Management Opportunities• Financing Options

ISO/TS 16949-2002 ISO 14001

ENERGY MANAGEMENT OPPORTUNITIES

• Installation of infrared ovens• Recover waste heat from air compressors• Tie HVAC units into Trane Tracer Summit• Repair compressed air leaks• Install power factor correction banks• Replace 250W high pressure sodium fixtures• Install occupancy controls on facility lighting• Replace compressed air agitators in plating

tanks

ISO/TS 16949-2002 ISO 14001

CURRENT ENERGY MANAGEMENT PRACTICES

• Use outside air for compressor intake

• Purchase premium efficiency motors

• Reduce steam pressure from 100psi – 80 psi

• Use infrared ovens

• Use timers on conveyor motors

• Reduction in compressed air pressure

ISO/TS 16949-2002 ISO 14001

INCREASE THE CAPACITOR BANK ON ELECTRICAL SERVICE ENTRANCE

BEFORE-

Description: Electric Service Entrance

Problem: Power Factor below 90% resulting in penalty charge on electric bill

ISO/TS 16949-2002 ISO 14001

INCREASE THE CAPACITOR BANK ON ELECTRICAL SERVICE ENTRANCE

AFTER:

Description:

Electrical service entrance with additional 300 KVAR capacitor bank

Savings: Energy charges reduced $ 9,580.00 annually

ISO/TS 16949-2002 ISO 14001

IMPROVE EFFICIENCY OF PROCESS STEAM BOILERS

BEFORE:

DESCRIPTION:

Boiler #1 fire tubes during annual inspection

PROBLEM: Wasted heat results in higher gas stack gas temperatures and heat loss

ISO/TS 16949-2002 ISO 14001

IMPROVE EFFICIENCY OF PROCESS STEAM BOILERS

AFTER:DESCRIPTION:

Installation of “ fuel saver” turbulators reduce lost heat

COST SAVINGS: An annual energy savings of $ 9,940 was realized in reduced energy usage.

ISO/TS 16949-2002 ISO 14001

• Brake pads exiting the powder paint spray booth make their way by conveyor toward the infrared cure oven

ISO/TS 16949-2002 ISO 14001

EUROPEAN UNIONSUBSTANCES OF CONCERN

• In August of 2002, ABE began the conversion from hexavalent to trivalent chromium solutions on the first of ten zinc plating processes.

• Since 2002, seven zinc plating system have been converted to trivalent chromium with the remaining systems planned for completion by July 2007.

ISO/TS 16949-2002 ISO 14001

• The interior of a zinc plating system where trivalent chromium is applied to a disc brake

ISO/TS 16949-2002 ISO 14001

PROCESS MODIFICATIONS

• In 2003 , ABE installed its first powder paint system to begin the phase out of the solvent based painting process for pressure plates.

• Powder paint Line 2 was installed in April 2005 to complete the removal of four solvent based

painting systems

ISO/TS 16949-2002 ISO 14001

ENVIRONMENTAL BENEFITS

• A reduction of 6 tons / year of VOC and HAP emissions were realized with this

process change

• 15 tons / year reduction in hazardous waste generated from the liquid paint process

from 2003 thru 2006

ISO/TS 16949-2002 ISO 14001

0

20000

40000

60000

80000

100000

120000

140000

160000

180000

Po

un

ds

VO

C

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Years

Akebono - Elizabethtown VOC Emissions

Backing Plate Paint ( drum brake)

E015 / E016 P/P Adhesive

E014 Pressure Plate Primer

Hamatite Adhesive ( brake lining)

Methyl Ethyl Ketone thinner

Sundine 685W Primer

Pressure Plate Painting

TCE Batch Vapor Cleaning

Pow der Paint Line 1 Installation

Pow der Paint Line 2 Installation

Honda Approval for Pow der Paint

Surface Treatment 1 Conversion to Pow der Adhesive

Surface Treatment 2 conversion to Pow der Adhesive

ISO/TS 16949-2002 ISO 14001

ELECTROLESS NICKEL PLATINGBATH TREATMENT

Reduce Nickel Concentration by 90% in Spent Plating Baths Prior to Discharge into Onsite Pretreatment

Plant

Plate Out the Spent Bath on Metal Shavings Generated from the Manufacturing of Pistons used in the Disc

Brake Applications

Nickel Coated Metal Shavings Sent to Recycling Facility

ISO/TS 16949-2002 ISO 14001

ISO/TS 16949-2002 ISO 14001

ISO/TS 16949-2002 ISO 14001

ISO/TS 16949-2002 ISO 14001

Akebono – Elizabethtown

Plant received the inaugural

Kentucky Excel award in

May 2006 at the Master

Level

Akebono- Glasgow Plant

Received the the Kentucky

Excel award in April 2007 at

The master level.

Akebono- Springfield Plant

Received the Kentucky Excel

Award in April 2007 at the

Leadership level.