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Green Materials Initiatives at Cummins
Sanjay Thakur - Cummins International

Sanjay was appointed to be part of a Green Materials Engineering Group. The group found itself exploring largely new and undefined ground. A main chore was defining "green"; deciding what and "initiative" is, and how it is implemented; and how material's processes can be refined to become "green".

A working definition of "green" was arrived at, inclusive of the following:
       reduced carbon emissions
       reduced energy use
       long term sustainability (renewable resources)
       exclude certain environmentally harmful elements

A Star Point group was assigned to wrestle Environmental Sustainability under a Global Master Black Belt. The targets of this effort involves three points of interaction:
       Product and Processes
       The Supply Chain
       Work Places

In the selection of materials environmentally sustainable elements (considering their carbon footprint) are to be considered.

So far four distinct initiatives have been conceived.

       Recycling of polymers
              remelting & reshaping
              Problems include lower properties, and contamination issues
              An advantage is cost-saving.

       Glycerin Based Coolants
              these are a bi-product of biodiesel production
              non-hazardous classification

              disadvantage - higher viscosity.

       Aquence - e-coat primer
              replaces zinc phosphate
              no heavy-metal toxics

       KATS - Coated engines
              clear coat paint with environmentally friendly coating
              less greenhouse gas generation
              less masking
              reduces acetone use

The group (MEFE) developing these initiatives is a mix of engineers from the material, chemical, and quality disciplines. It began work as a "brain storming" session which identified several objectives:
       Develop standard tools for CO₂ calculations
       Interface with manufacturing processes
       Develop material selection guidelines for CO₂ reduction.
       define a purchasing checklist
       coordinate with education and research efforts
       develop a consciousness for CO₂ footprint in designs
       understand the end-of-life cycle for targeted components

In the area of "tools for CO₂calculation", the EPA website was found to be extremely useful: epa.gov/cleanenergy/energy-resources]calculator.html

In the area of "manufacturing initiatives", four have been previously cited. Two are currently in implementation, the other two are being worked toward.

There is a strong need to get Quality and Purchasing involved early in the process. This will avoid surprises later.

Guidance documents for design engineers and training modules in "e-friendly" methods must be developed.

There is a desire to develop additional resources but working with experts and developing a "six-sigma" style database of information.