When it comes to environmental protection, employees at the SKF facility at Flowery Branch, Georgia, recycle, reclaim, reuse – and refuse to give up on any possible project that can help them reach their goal of zero waste.Since 1995, efforts toward zero waste at one SKF facility have gained steam, as success after success has proven that waste reduction can result in both a better environment, and a better bottom line.
   In Georgia, near the foothills of the Blue Ridge Mountains, close to beautiful Lake Sidney Lanier, lies the appropriately named town of Flowery Branch – a place where residents enjoy the outdoors and have an appreciation for the natural environment. Like many rural communities, this area is also home to major industries – one of them being SKF. Here, deep groove ball bearings are manufactured – and a variety of waste streams, ranging from water to steel, are generated. Today, the SKF Flowery Branch facility is in its seventh year of a highly successful waste stream reduction effort. The facility’s efforts have recently been recognized with a major environmental award from the state of Georgia. But, for plant management and employees, the real reward has come from the lessons learned and dollars saved as they pursue new ideas for eliminating waste, protecting their environment – and improving business operations.

A zero waste directive
In 1995, SKF directed all facilities to work towards zero waste by the year 2000.
   “Our initial reaction was that there was no way we could get to zero,” notes Ed Bennett, now vice president and general manager of the facility. “But, we accepted the target, set our goals accordingly and got started by establishing a Waste Reduction and Recycling Team.” Employee participation in the effort was voluntary, and Bennett admits that interest at the outset of the program was minimal. “There was a lack of understanding of waste streams by the general employee population,” he notes. “It took some time before we had a team in place who really understood the impact the program could have and who were willing to commit the time and effort necessary.” One of those team members was Purchasing Manager Mary Perdue, who has been part of the waste reduction effort since its inception. “We were rookies,” she says. “But we learned. And with each success, we become more enthusiastic.” Today, the program is in full swing. A training program has been established to educate all employees and new hires about the recycling and handling of waste products. And the Waste Reduction and Recycling Team continues to meet monthly to identify and pursue waste reduction targets.

From waste, financial savings
Like any investment, the waste stream reduction effort required start-up funds. Ed Bennett notes that, “Initially, that was a big pill to swallow, considering all the other projects we had looking for funds. But, cost benefit analysis suggested significant payback potential – so funds were allocated.”
   After seven years, the payback has been excellent, as the program has both saved money and generated income. Since 1995, the plant has reduced waste streams by 60percent. In doing so, they are realizing a savings of at least $100,000annually, while at the same time generating income from the sale of recyclable materials.
   This year, for example, the facility expects to save $90,000 earmarked for the disposal of wastewater by finding a way to reduce the amount of wastewater generated.
   Along with enhancing the bottom line, Manager of Manufacturing Systems Jim Lewis believes that recycling and waste reduction efforts have also streamlined and improved operations. “The waste stream reduction program has forced us to look closely at all areas of our operations,” he says. “In trying to reduce waste, we’ve analyzed everything from employee work methods to machine operations – and we’ve found ways of improving both.”
Point source reduction, recycling are key Lewis notes that while it’s easy to see waste in its final form, it’s not so easy to pinpoint exactly how that waste can be reduced or eliminated. “There are no real shortcuts,” says Lewis. “We found that the best way to really understand how the waste is generated is to start at the beginning of a process and analyze each step of the process to see where, why and how the waste is being generated.” This process, known as “point source reduction,” has been a key element in minimizing the amount of waste produced.
   Since it is virtually impossible to eliminate all waste, a secondary point of attack is determining the most environmentally responsible method of disposing of the waste that is generated. For Flowery Branch employees, the answer has been recycling.
   “We found many alternatives to having waste hauled away or sent to a landfill,” notes Mary Perdue. “Much of our waste – scrap balls and grinding wheels, for example – is now sent to recyclers, or to suppliers who rework and reuse the material in their own operations.” Other efforts involve rethinking how materials are used, and developing less wasteful methods. “We used to use non-recyclable, single-use wooden pallets,” says Perdue. “We would ship them out with product and never see them again. Now, we have reusable modular pallets that are used over and over.” Other efforts are much simpler – such as giving each office employee a trash can for recyclable materials. “Some things are just common sense,” says Perdue. “But, it takes someone to get the ball rolling.”

Rewards in recognition
The Flowery Branch facility waste reduction efforts have earned the facility recognition from customers, suppliers, the local community and the state of Georgia. “Many of our customers and suppliers have the same issues and come to us for help and advice,” says Jim Lewis, “It’s enabled us to developed better relationships with them.”
   Locally, the plant’s efforts have positioned SKF as a community leader in environmental responsibility. Most significantly, for the second year, the state of Georgia has honored the facility with a first place award for Waste Minimization, as part of the state’s Keep Georgia Beautiful conservation and recycling initiative. The award recognized SKF for its success in reducing waste and in educating employees and community members about environmental preservation.

Employees make the difference
What started as a directive for the Flowery Branch facility has become a passion for many employees. “Every person who is on the Waste Reduction and Recycling Team does so on a volunteer basis,” notes Jim Lewis. “And that’s what has made our program so successful. Each of our volunteers has a true interest in preserving the environment.”
   “Management has been extremely supportive of our efforts,” adds Mary Perdue, “in terms of funding and allowing us the time to work on our projects. Even though this is a company effort, for me, the motivation is personal. I’m doing this for my grandchildren. I want them to enjoy this beautiful Georgia environment just the way I have.”