Firestone Agricultural Tire Company 2003 APR View/Print

OMB No. 2010-0032
Expiration Date 01/31/2010

2003 Performance Track Annual Performance Report

Firestone Agricultural Tire Company
A070012
Year 3 Annual Performance Report

SECTION A: GENERAL FACILITY INFORMATION

A.1	Name of your facility:
	Firestone Agricultural Tire Company
A.2	Name of your parent company:
	Bridgestone Americas Holding, Inc
A.3	Facility contact person for the Performance Track program:
	Name:	Mr. Dain Brandrup
	Title:	Utilities/Environmental Engineer
	Phone:	(515) 243-1211 x 5258
	Fax:	(515) 237-5695
	Email:	brandrupdain@firestoneag.com
A.4	Facility location:
	Street Address:	Second Avenue & Hoffman Road
	Address Cont:
	City:	DesMoines
	State:	IA
	Zip Code:	50313
	Mailing address (if different from above):
	Mailing Address:	PO Box 1295
	Address Cont:
	City:	Des Moines
	State:	IA
	Zip Code:	50305
A.5	Facility's website address (if any):
	http://www.firestoneag.com
A.6	Number of employees (full-time equivalents) who currently work in the facility:
	More than 1,000
A.7	North American Industrial Classification System (NAICS) Code(s) that is(are) used to classify business at the facility:
	326211
A.8	In your application and, perhaps, in previous annual performance reports, you described what your facility does or makes. Have there been any (additional) changes to your facility's list of products and/or activities? If yes, please list them here:
	No Changes

A.9	Have the environmental requirements applicable to your facility changed during this reporting period? If yes, please describe these changes here.
	No Changes

SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

B.1.a	When was an EMS assessment last conducted by an independent party at your facility?
	2003
	If an assessment was conducted during 2003, please provide the type (e.g., ISO 14001 certification), the scope, and the month(s) of each assessment.

Type	Scope	Dates
ISO 14001 Surveillance	Mandatory Items, Document Control, Cell 4 (Receiving, Cement Room, Tubers and Calendering Departments) - All ISO 14001 Standard Elements	April 2003
ISO 14001 Surveillance	Mandatory Items, Environmental Records, Banbury Mixing (Department 412), Cell 1 (Stock Cutting, Bead Building, Tire Building, Curing and Final Departments), Contractor Management and Purchasing Department - All ISO 14001 Standard Elements	October 2003

B.1.b	When was an internal EMS assessment last conducted at your facility?
	2003
	If an assessment was conducted during 2003, please provide the scope and month(s) of each assessment.

Scope	Dates
April 2003 - Calendering Department (422), Tubing Department (426)	April 2003
May 2003 - ER Shop June 2003 - Engineering, Human Resources July 2003 - Information Technology	May 2003
September 2003 - Purchasing Department, Cell 1 (Stock Cutting, Bead Building, Tire Building) October 2003 - Banbury Mixing Department (412), Safety and Security Departments, Cell 2 (Stock Cutting, Bead Building, Tire Building, Curing and Final Departments), Process Engineering	September 2003
November 2003 - Maintenance (831), Powerhouse (651), Warehouse (793), Cell 1 (Curing, Final, Mold Change and Bladder Press Departments)	November 2003

B.1.c	When was an internal or corporate compliance audit last conducted at your facility?
	2003
	If an audit was conducted during 2003, please provide the scope and the month(s) of each audit, and indicate who conducted the audit(s) (e.g., facility staff, corporate groups, third party). (Don't include audits, inspections, or site visits by regulatory or external organizations).

Scope	Dates	Who conducted the audit
Air Quality Management, Water Discharges, Waste Management, Chemical Review Processes, Energy Management, Facility & Grounds Issues, Emergency Preparedness	December 2003	Dan Smidt - Montgomery Watson Harza (MWH)

B.1.d	(Optional) If you would like to describe any other audits or inspections that were conducted at your facility, please do so here.
	Annual inspection by Brent Blanchard from Polk County Air Quality on 08-13-03. The scope of the audit included a file review and an inspection of the facility's permitted emission points. No items of concern were noted during the inspection. Annual inspection by Larry Hare from the Waste Water Reclamation Authority (WRA) on 11-13-03. The inspection included a file review and an inspection of the facilty. No items of concern were noted during the inspection.
B.1.e	Briefly summarize corrective actions taken and other improvements made as a result of your EMS assessments and compliance audits.
	Changes and improvements resulting from EMS assessments and compliance audits were mostly minor procedural or document type continual improvement changes.
B.1.f	Has your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?
	No
	Several non-compliance and non-conformance items were identified during the facility's December 2003 compliance audit. Items not completed immediately were noted, corrective actions outlined and a schedule created for the implimentation of corrective actions.
B.1.g	When was the last Senior Management review of your EMS completed?
	December 2003
	Who was the senior manager present at the review?
	Name: Mr. David A. Dirks
	Title: Operations Manager

B.2.a

ISO 14001 Certification. Is your facility currently certified to ISO 14001?

Yes

B.2.b

Is your facility a Responsible Care-certified facility?

B.3

Environmental Aspects Identification. When did your facility last conduct a systematic identification and/or review of your environmental aspects?

October 2003

B.4

Progress Toward Achieving Objectives and Targets. In the table below, please provide a narrative summary of progress made toward EMS objectives and targets other than those reported as Environmental Performance Commitments in Section C. You may limit the summary to environmental aspects that are significant and towards which progress has been made during the reporting year. Do you have additional environmental aspects to report? Yes

Environmental Aspect	Progress Made This Year (e.g., quantitative or qualitative improvements, activities conducted)
Solid Waste Recycled Percentage	Exceeded the target of recycling 50% of all wastes (actual 60.0%). This was accomplished through the continuation of existing recycling programs for such wastes as: scrap metal, used oil, hydraulic oil, wood pallets, cardboard, paper, mixed pigments and scrap tires. Additionally, FSAG initiated recycling of un-cured green rubber via third party recycling companies (one in IA and the other in TN) and refocused efforts upon the internal recyling of un-cured green rubber via remilling and refining.
Landfill Disposal Indexed to Production	Exceeded the target of landfilling less than 23.8 pounds of waste per 1,000 pounds of production (actual 22.3 vs. 26.2 in 2002). This was accomplished by the renewed recycling efforts described above and by reducing waste and scrap as generated in individual departments throughout the facility.

SECTION C: ENVIRONMENTAL PERFORMANCE COMMITMENTS

COMMITMENT 1


Category:	Product Performance
Aspect:	Packaging Materials Used in Product
	Baseline	Year 1	Year 2	Year 3	Performance Commitment
Calendar Year:	2000	2001	2002	2003	2003
Actual Quantity (per year):	2,007,400	458,400	212,180	60,960	1,003,700
Measurement Units:	lbs	Other:
Normalizing Factor:	1.0	0.89	0.99	1.03	1.0 *
Basis for your Normalizing Factor:	Production data
Normalized Quantity per year:	2,007,400	515056.18	214323.23	59184.47	1003700

* Estimated

C.1.b	Briefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
	To accomplish this commitment the FSAG Purchasing, Quality Assurance, Receiving and Environmental departments worked with material / product suppliers to eliminate the utilization of wooden pallets for materials shipped to the facility. Now nearly all raw products are shipped in/on returnable containers or on recyclable cardboard pallets. Additionally, raw products (such as synthetic and natuarl rubber) received from intra-company providers are also now received in returnable containers (collapsable aluminum, good packs, returnable pallets/skids, etc.).
C.1.c	Please list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).

COMMITMENT 2


Category:	Air Emissions
Aspect:	Emissions of Toxics
	Baseline	Year 1	Year 2	Year 3	Performance Commitment
Calendar Year:	2000	2001	2002	2003	2003
Actual Quantity (per year):	0.9	0.72	0.68	0.24	0
Measurement Units:	tons	Other:
Normalizing Factor:	1.0	0.89	0.99	1.03	1.0 *
Basis for your Normalizing Factor:	Production data
Normalized Quantity per year:	0.9	0.81	0.69	0.23	0

* Estimated

C.2.b	Briefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
	Currently there are 9 products (striping and marking inks) identified that require reformulation. The Firestone Technical Center (ATC) in Akron, OH is responsible for approving all replacement materials to be trialed. In 2003 ATC rescinded all previous approvals to trial these replacement materials due to adhesion defects for the ribbon treading application. Starting over with the material vendor ATC approved 2 new "low solids" HAP-free striping inks for trial late in 2003. Contingent upon the success of the trial the other 7 materials will be trialed. 2003 reduction is due to vendor reduction of HAPs percentage.
C.2.c	Please list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).

COMMITMENT 3


Category:	Materials Use
Aspect:	Hazardous Materials Use
	Baseline	Year 1	Year 2	Year 3	Performance Commitment
Calendar Year:	1999	2001	2002	2003	2003
Actual Quantity (per year):	274,472	183,040	214,720	198,880	0
Measurement Units:	lbs	Other:
Normalizing Factor:	1.0	0.85	0.94	0.97	1.0 *
Basis for your Normalizing Factor:	Production data
Normalized Quantity per year:	274,472	215341.18	228425.53	205030.93	0

* Estimated

C.3.b	Briefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
	No progress in 2003. A replacement material (that has been formulated to be free of glycol ethers) has been identified and approved for on-site trials and testing, A 4,000 pound trial of the glycol ether free replacement material was completed successfully in 2002. Please note, a 1999 baseline was used for this commitment, therefore the normalizing factor based upon production data will be different than the other three commitments.
C.3.c	Please list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).

COMMITMENT 4


Category:	Energy Use
Aspect:	Total Energy Use
	Baseline	Year 1	Year 2	Year 3	Performance Commitment
Calendar Year:	2000	2001	2002	2003	2003
Actual Quantity (per year):	2,522,130	2,395,990	2,552,328	2,631,818	2,236,130
Measurement Units:	mmBtu	Other:
Normalizing Factor:	1.0	0.9	0.99	1.01	1.0 *
Basis for your Normalizing Factor:	Production data and Heating Degree Days (HDD). Energy Usage can be divided into three categories: 1. Baseload - energy to run the facility but produce no product 2. Production - energy required to produce products 3. Heating Load - energy required to heat the facility in the winter. The heating load is accounted for in the budget, based upon average HDD for Des Moines, IA. HDD is a useful energy index that is defined as the difference between 65 degrees F and the mean daily temperature. For example a day with a mean daily temperature of 66 F would produce 0 HDD, while a day with a mean daily temperature of 61 F would produce 4 HDD. NOAA publishes the average HDD for certain areas on a daily and monthly basis. These are useful for determining building heating loads in different climates and for determining the mildness or serverity of the heating season based upon temperature.
Normalized Quantity per year:	2522130	2662211.11	2578109.09	2605760.4	2236130

* Estimated

C.4.b	Briefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
	Total energy usage was higher in 2003 as compared to 2002. Despite undertaking many energy savings projects; most significantly the completion of 19 insulation projects for annual savings of 29,717 MMBtu and $207,245 the efforts for this commitment fell far short of the lofty initial goal. (Had these projects not been completed the increase in energy usage would have been greater).
C.4.c	Please list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING


D.1	Please briefly describe the activities that your facility conducted during the year to interact with the community on environmental issues and to report publicly on environmental performance.
	FSAG communicates pertinent information regarding our facility via many different methods. The following are a few examples of typical public outreach and reporting completed by FSAG in 2003: FSAG hosted an open house in June of 2003. The open house was by employee invitation and over 1,000 people took the opportunity to tour our facility, check out our tires, see the equipment FSAG supplies OE tires for, have fun, enjoy some good food and meet celebrity guest Mario Andretti. FSAG also provides facility tours and information throughout the year to suppliers, customers, civic groups and schools. FSAG also contributed to the Variety Club of Iowa and participated in the Variety Club's telethon, supplying volunteers to man the phones. Additionally, FSAG salaried and hourly employees contribute to the United Way and American Red Cross annually. Lastly, Bridgestone/Firestone was awarded the 2003 HONDA of America Manufacturing, Inc Green Partner Award (FSAG was one part of a five facility application/nomination). HONDA presents this environmental award annually to its top performing supplier (1 of 461 companies). To publicize receiving the Green Partner Award several internal and external press releases were issued. Some examples include: articles in the Network newsletter distributed to all Bridgestone Americas employees and in the Daily Oklahoman newspaper. FSAG also participated in an awards cermony in Oklahoma City, OK for the HONDA Green partner award which was attended by local and state politicians and the media.
D.2	Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public.
	Web Site
	URL: http://www.epa.gov/performancetrack/particip/alphabet.htm

Attachments (if applicable) :