Manufacturing has been rapidly taking on a new image in the US. Far from being the stereotypical dirty and dangerous death trap it is often envisioned as, it is becoming increasingly high-tech and sustainable. That was the goal Ford set out with when they designed their Dearborn facility where the F-150 is built. 10 years later, sustainability is still a top priority.
According to a Ford Motor Company press release, “The Dearborn Truck Plant has produced more than 2.6 million F-150 trucks since it opened in May 2004.” That is a lot of product, and that means a lot of opportunity to make a difference. There are some other large numbers that are worth reciting as well.
20 million pounds. That is the amount of paper, cardboard, plastic and wood they’ve recycled at the plant since its inception. This is partially attributed to the philosophy of using as much recyclable material as possible, but they also have a grander waste management plan which addresses areas of transportation, disposal, recycling, reclamation and reuse of plant waste.
Some other aspects they’ve addressed include raw materials used in finishing and facilities operation. They use water-based primer and base coat in their paint department to reduce volatile compounds. To control building temperature and lighting they enlist nature. Plenty of natural light and ventilation keep the plant comfortable as the 3,600 employees put out 1,200 trucks a day.
Another way they are enlisting nature is on the roof. All 10.4 acres of it. In addition to supporting its own ecosystem, the living roof (or green roof) is providing carbon capture and reducing energy costs. It is also part of an integrated storm water management system. That system is designed to mitigate runoff and costs two-thirds less than comparable treatment through conventional systems.
The plant is not the end of positive environmental impacts manufacturing can have. As fuel efficiency and emission standards become increasingly stringent, there has been a revolution in vehicle design. Design engineers are stepping up to the challenge by innovative design and “uncommon” use of materials.
Although a “pig iron” impression of trucks might lend to their rugged image, that doesn’t cut it anymore. Expanded use of high-strength steel and aluminum has cut 700 lb from the 2015 F-150, without compromising performance. Evidence that simply adding more material does not equal more “truck.”
Although Ford hasn't gone to the extreme of producing a modern wooden car, like the BioFore Concept, big differences can start with "small" steps. There are obviously a variety of factors which guide major manufacturers to use sustainable practices such as cost, regulation and reputation. No matter what the cause, it is encouraging to see adoption - and success - of sustainable methods in modern, mainstream manufacturing.
The video below describes the 10 year anniversary of the Ford Dearborn Truck Plant.
Images courtesy of Ford Motor Company