Issues: Cost Reduction, Environment, Well-being, Energy, Natural Resource Management
Stakeholders: Employees, Communities, Suppliers
Region: North America
Teamwork and ingenuity have helped Novelis’ light gauge plant in Fairmont, West Virginia raise its reclaimable oil levels from 3,000 gallons to more than 50,000 gallons, an improvement that lowers environmental, health and safety (EHS) risks while reducing costs.
Using Continuous Improvement methodology, a team of maintenance and operation managers came together to determine a solution to reduce the plant’s storage of used oil. Implementing alternatives to storage would, in turn, decrease the risk of leaks and other environmental hazards and allow the plant to maximize its reuse of the used oil.
Within four months, a new reclamation system was put into place, which isolates the mill coolant oil and re-routes it for reuse in the production process. A monitoring system was also installed which draws attention to excessive oil usage. These systems combine to reduce oil purchases and decrease the environmental risk from storing used oil. This process also delivers significant cost savings. In 2006, the Fairmont plant saved an estimated $250,000 and will continue to enjoy cost savings as its improved energy efficiencies and decreased oil purchases are realized.
