The Ford Oakville Assembly Complex (OAC) is one of the first to implement flexible manufacturing and deploy a real-time location system using radio frequency identification (RFID) technology. To manage compliance with Canadian environmental regulations and Ford's internal policies, the OAC had implemented an environmental management system (EMS) based on the ISO 14001 standard. As the company moves forward with plans to improve its environmental performance and realize cost savings, OAC looked to Geosyntec for support in improving its EMS, maintaining environmental compliance, and addressing environmental issues in anticipation of suspension of manufacturing activities as this 5.4 million-square foot complex transitions into the manufacturing center for Ford and Lincoln branded crossover (2007) and hybrid crossover (2010) vehicles.
Geosyntec's Scope of Services
Geosyntec personnel have supported EMS implementation at a number of Ford manufacturing facilities. In mid-2004 as part of the redevelopment of the OAC, Ford shut down the former Oakville Truck Plant manufacturing line. Ford called upon Geosyntec to evaluate the environmental compliance requirements for plant shutdown in a compressed timeframe. Geosyntec conducted a detailed review of federal, provincial, and regional environmental regulations applicable to shutdown activities. Using EMS documentation developed earlier by Geosyntec personnel, a management plan was developed for waste disposal and material reuse/recycling. Geosyntec developed a checklist to be used by waste management contractors to quantify materials, track their disposition, and document conformance with EMS procedures. Using the plan developed by Geosyntec, Ford's contractors completed plant shutdown with waste management documented in accordance with Ontario regulations. Geosyntec provided ongoing EMS and environmental compliance support to Ford OAC resulting in continual improvement in environmental performance metrics, such as reductions in VOC emissions, packaging waste, and energy use. With its extensive experience at the facility, Geosyntec has provided ongoing EMS and environmental compliance support to Ford OAC as the facility transitions to the manufacturing center for 2007 hybrid crossover vehicles for Ford and Lincoln brands.
With Geosyntec's participation, the Ford OAC EMS has been regularly recertified to the ISO 14001 standard with no system non-conformances. Ford OAC has eliminated PCB-containing transformers, reduced energy use, reduced packaging waste, recycled copper, reduced water use, and reduced VOC emissions. The OAC Plant Shutdown Environmental Compliance Assurance matrix and associated checklist developed by Geosyntec have been utilized as a Ford Best Management Practice.