Ford powertrain operations save money, boost quality

Ford Motor Company's Livonia (Mich.) Transmission Plant is dramatically reducing the use of costly metal-working fluids through a new Minimum Quality Lubrication (MQL) process. Combined with other "green" procedures at powertrain facilities in Ohio, Canada and Mexico, Ford anticipates annual savings of up to $2.8 million.

"Our Powertrain facilities are doing an excellent job with sustainability practices," said Barb Samardzich, vice president, Ford Powertrain Operations (PTO). "They're delivering positive results for the environment, for the communities where we do business and for our shareholders."

MQL, a North American industry-first process, is being used at Livonia Transmission to make the company's six-speed automatic rear-wheel-drive transmission (6R) for the Ford Explorer and Mercury Mountaineer. Samardzich says that besides lowering costs and reducing the impact on the environment, MQL is also shortening the manufacturing cycle time and boosting quality.

"It used to be that environmental actions were considered only a cost burden," said Mark Blair, Ford director of PTO manufacturing engineering (ME). "Now we know that you can save money and improve both the external and manufacturing environments."

An innovative vacuum carburizer process for heat-treating transmission gears has replaced gas-fired furnaces at Ford's Sharonville, Ohio, facility. The new process is cleaner, heats more evenly and improves part quality. It is expected to save more than $1 million annually, once fully implemented.

Ford's Lima, Ohio, facility is using naturally cold reusable groundwater from an abandoned quarry to create air-conditioning for the plant and also to cool manufacturing equipment. The geothermal process significantly reduced the use of mechanically chilled municipal water, reducing energy consumption and carbon emissions.

"Processes like MQL, geothermal and vacuum carburization address environmental issues and save on cost," Blair said. "Powertrain wouldn't have been successful in implementing these processes without the commitment and hard work of our people in the plants, our ME group, and in Advanced Manufacturing Technology Development."

Blair added that the Livonia and Sharonville facilities collaborated with PTO Manufacturing and Engineering along with the Advanced Manufacturing Technology Development team to develop sustainable procedures.

Canada's Windsor Engine facility anticipates annual savings of more than $1 million annually through simple energy conservation measures. By turning off unnecessary lights, closing doors and shutting down machines and pumps during off times, the plant is on track to more than double its energy reduction objective. It also reduced its compressed air consumption by 45 percent by shutting off unnecessary equipment and repairing leaks.

In drought-plagued Mexico, Ford's Chihuahua plant slashed its potable water consumption by nearly 75 percent between 2000 and 2005. By using diesel generators during peak hours along with other measures, the plant also reduced its energy costs by 27.5 percent for a projected savings of $608,000.

"As the cost of energy continues to escalate the cost benefit to sustainability projects becomes more substantial," said Linda Miller, director of manufacturing, PTO. "Powertrain is taking a strong stand on the environment and reducing its manufacturing cost, which is outstanding."

PTO is rolling out an Environmental Operating System, over the next two years, designed to maximize environmental responsibility in manufacturing.

"It's a forward look and not a reactive look," said Terry Aldea, PTO manufacturing and engineering manager and environmental champion. "We're trying to give environmental the same amount of attention and due diligence that we’ve always given to safety."