Karl Schmidt Unisia, Inc. Fort Wayne Facility 2007 APR View/Print

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

2007 Performance Track Annual Performance Report

Karl Schmidt Unisia, Inc. Fort Wayne Facility
A050086
Year 3 Annual Performance Report
Member Since 2005 (1st Member Term)

SECTION A: GENERAL FACILITY INFORMATION

A.1

Name of your facility:

Karl Schmidt Unisia, Inc. Fort Wayne Facility

A.2

Name of your parent company:

Karl Schmidt Unisia, Inc.

A.3

Facility contact person for the Performance Track program:

Name:	Mr. Tony Martin
Title:	Director of Environmental, Health and Safety
Phone:	(260) 467-8276
Fax:	(260) 423-2141
Email:	tony.martin@kus.com

A.4

Facility location:

Facility Address

Street Address:	2425 Coliseum Boulevard South
Address Cont:
City:	Fort Wayne
State:	IN
Zip Code:	46803

If your facility has multiple street addresses, please list any other addresses for its sites or buildings.

A.5

Facility's website address (if any):

http://www.kus.com

A.6

Number of employees (full-time equivalents) who currently work in the facility:

50-99

A.7

For the purposes of where your facility would be listed in our Member Directory, please list the North American Industrial Classification System (NAICS) Code(s) that is (are) used to classify business at the facility:

Primary	Secondary	Tertiary	Quaternary	Quinary
336311

A.8.a

List the activities, products, or services that take place at your facility:

Manufacture pistons for the automotive market. We cast, machine, coat and assemble pistons.

A.8.b

Provide the size and general description of your site:

We have approx. 30 acres, with several buildings on the land.

A.9

Have the environmental requirements applicable to your facility changed during this reporting period?

SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

B.1.a

Is your facility certified to ISO 14001?

Yes

B.1.b

Is your facility's EMS (not your corporate office's EMS) certified to the American Chemistry Council's Responsible Care® program (i.e., has your facility successfully undergone a Responsible Care® third-party audit)?

B.2

Performance Track members must have their EMS assessed by an independent party at least once every three years. Please indicate the details of the most recent independent assessment conducted at your facility. If your most recent independent assessment did not cover all EMS elements and business areas, please use the "Add Assessment" button to indicate the additional partial assessments.

Independent EMS Assessment #1

When was this EMS assessment?

July 2007

What protocol was used?

ISO 14001 Standards
Specify:

Who conducted the audit?

Name:	Ernie Blanchard
Title:	Senior Auditor
Organization:	TUV Rheinland of Noth America

Which EMS elements were included in the audit?

Policy, Planning, Implementation, Checking, Management

Did the assessment cover the entire facility or part of the facility?

Entire Facility

Which business areas were included in the audit?

B.3

EPA recommends that Performance Track members conduct an internal EMS assessment every year. Did you conduct one in calendar year 2007?

Yes

Internal EMS Assessment #1

When was this EMS assessment?	May 2007
Which EMS elements were included in the audit?	Policy, Planning, Implementation, Checking, Management
Did the assessment cover the entire facility or part of the facility?	Entire Facility

Internal EMS Assessment #2

When was this EMS assessment?	November 2007
Which EMS elements were included in the audit?	Policy, Planning, Implementation, Checking, Management
Did the assessment cover the entire facility or part of the facility?	Entire Facility

B.4

EPA recommends that Performance Track members conduct a regulatory compliance audit every year. Did your facility conduct any audits in calendar year 2007 to verify compliance with regulatory statutes?

Yes

Regulatory Compliance Audit #1

When was this regulatory compliance audit?	December 2007
Which regulations were included in the audit?	Clean Air Act (CAA) Clean Water Act (CWA) Emergency Planning & Community Right-To-Know Act (EPCRA) Resource Conservation and Recovery Act (RCRA) Toxic Substances Control Act (TSCA) Underground Storage Tank (UST) Regulations

B.5

Please describe any other audits, inspections, or facility reviews conducted at your facility during the previous three years.

Indiana Department of Environmental Management did audit and inspection for the Indiana Environmental Stewardship Program on January 5, 2007. EPA capactor inspection on June 1, 2006. IDEM air inspection on October 28, 2005. IDEM industrial waste inspection on June 14, 2005.

B.6.a

Has your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?

Yes

B.6.b

Performance Track members should have a Senior Management Review of their EMS every year. Did this review take place in calendar year 2007?

Yes

Who was the senior manager present at the review?

Name: Mr. Mark Lennart

Title: Vice President of Operations of North America

B.6.c

Performance Track members should conduct a systematic identification and/or review of their environmental aspects at least once every two years. When was your last one conducted?

May 2007

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

Goal 1: Karl Schmidt Unisia, Inc. Fort Wayne Facility's first goal is to reduce the facility's total water use.
C.1.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	We have added a preventive maintenance program for the cooling towers and water related pumps, etc. We track this through a main saver computer program in the maintenance department.
	Activities Conducted During 2006:
	We are reviewing water usage and using action plans to keep this commitment on track.
	Activities Conducted During 2005:
	Use the facilities cooling towers to cool and recirculate water internally, rather than continuous use of City water and subsequent discharge to city drains. We changed our original commitment to a more stringent goal, do to better than expected results from the use of our cooling towers. We are now also focusing on other improvements.
C.1.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	We log and chart the gallons used monthly, from the meter reading, by the City of Fort Wayne.
C.1.c	Please report your facility's actual performance.

Performance Data
	Baseline	Year 1	Year 2	Year 3	Perform.
Calendar Year	2003	2005	2006	2007	Goal	Units
Actual Quantity (per year)	35,360,000	16,055,000	21,197,000	20,941,000	n/a	Gallons Specify other:

C.1.d

Normalized progress toward goal.

Normalized Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	.88	.90	.93
Normalized Quantity	35,360,000	18,244,318.18	23,552,222.22	22,517,204.30	24,000,000	Gallons Specify other:
Basis for your Normalizing Factor:	The facility will reduce water usage gallons facility wide. The normalizing factor is based upon the pounds of pistons produced per year.

Goal 2: Karl Schmidt Unisia, Inc. Fort Wayne Facility's second goal is to reduce the facility's generation of non-hazardous waste, specifically baking soda.
C.2.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	We have added a preventive maintenance program for key coating equipment. This helps to target items before scrap or rework is generated. We meet with the team in this area, to go over results, new ideas or improvements they may have. Another new GM piston was brought in 2007 for coating only. The startup was higher than normal for scrap & rework before the process was refined. This caused the actual and the normalized to be higher than the year before.
	Activities Conducted During 2006:
	There are four different six sigma teams working on scrap reduction that will help this commitment. Note: normalizing factor of 1.56 is correct, a new operation was brought in January 2006 to only coat a piston that is shipped in for this operation only, where baking soda is used on scrap coated pistons. We still have the original piston that we produce from the molding stage through the coating process.
	Activities Conducted During 2005:
	Six Sigma project was used for this commitment. Reduction of piston coating scrap at this process, requiring less baking soda to remove coating and rework the product. We changed our original commitment to a more stringent goal, do to better than expected results from the six sigma project.
C.2.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	We use the scrap or rework pistons for our computer SAP system to get daily, weekly or monthly results. Baking soda is brought in by 100 # bags and the amount would be hard to break down any farther for useful data.
C.2.c	Please report your facility's actual performance.

Performance Data
Waste Management Method	Baseline	Year 1	Year 2	Year 3	Units
Waste Management Method	2003	2005	2006	2007	Units
Landfill Specify other:	18,000	10,000	2,500	3,000	Pounds Specify other:
Specify other:					Specify other:
Specify other:					Specify other:
Specify other:					Specify other:
Specify other:					Specify other:

C.2.d

Summarized progress toward goal.

Actual Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Non Hazardous Waste	9.00	5.00	1.25	1.50	n/a	Tons Specify other:

Normalized Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	.80	1.56	1.18
Total Non Hazardous Waste	9.00	6.25	0.80	1.27	5.50	Tons Specify other:
Basis for your Normalizing Factor:	The normalizing factor is based upon pounds of pistons produced each year requiring anodizing.

Goal 3: Karl Schmidt Unisia, Inc. Fort Wayne Facility's third goal is to reduce the facility's discharges to water of toxics, specifically coolant (Houghton 795).

C.3.a Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.

This goal is complete with at least monthly inspections of this area.

Activities Conducted During 2006:

Our goal is to complete this project by the end of 2007. We review and inspect this area at least monthly.

Activities Conducted During 2005:

A dedicated closed trailer was sealed inside to prevent leakage of coolant, as the product is put inside. It trailer was sealed in April.

C.3.b Describe the data collection process and data source(s) that you used to measure progress towards this goal.

This area of the operation is no longer there. It was related to the loss of the Ford business.

C.3.c Please report your facility's actual performance.

Performance Data

Baseline Year 1 Year 2 Year 3 Perform.

Calendar Year 2003 2005 2006 2007 Goal Units

Actual Quantity (per year) 25 10 6 0 n/a Pounds

Specify other:

C.3.d Normalized progress toward goal.

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 .88 .90 .93

Normalized Quantity 25 11.36 6.67 0.00 10 Pounds

Specify other:

Basis for your Normalizing Factor:
Normalizing factor is based upon pounds of pistons produced per year.

Goal 4: Karl Schmidt Unisia, Inc. Fort Wayne Facility's fourth goal is to remove PCB-containing capacitors and replace them with non-PCB containing capacitors.

C.4.a Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.

This project is complete.

Activities Conducted During 2006:

We have now removed all know PCB capacitors, with the help of the electric company.

Activities Conducted During 2005:

Last capacitor containing PCB was removed and replaced with non-PCB containing capacitors at the Fort Wayne Facility by an outside environmental company.

C.4.b Describe the data collection process and data source(s) that you used to measure progress towards this goal.

We removed all of the capacitors a few years ago so we have none left on the site to measure/count.

C.4.c Please report your facility's actual performance.

Performance Data

Baseline Year 1 Year 2 Year 3 Perform.

Calendar Year 2003 2005 2006 2007 Goal Units

Actual Quantity (per year) 3 0 0 0 0 Pounds

Specify other:

C.4.d Normalized progress toward goal.

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1 1 1

Normalized Quantity 3 0.00 0.00 0.00 0 Pounds

Specify other:

Basis for your Normalizing Factor:
n/a

Progress Towards Other Significant Aspects of your EMS

In the table below, please provide a narrative summary of progress made toward EMS objectives and targets other than those reported as Environmental Performance Goals. 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? No

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

D.1.a Please describe your process to identify potential community environmental concerns.

Informational number established for telephone calls requesting information or submitting complaints regarding the facility. All telephone calls are logged by security, reviewed as they happen, and also reviewed at our yearly management review.

D.1.b If you identified community environmental concerns, how did you respond to them?

None were identified. If there were, we would have newspaper submittals, as required by regulatory agencies or other requests. We also inform or keep informed the Harvester Community Association, which is the local association.

D.1.c Please describe how you informed the community about environmental matters related to your facility.

We would have newspaper submittals as required by regulatory agencies or other requests. We inform the Harvester Community Association. We informed them of the facility becoming a Charter member of the Indiana Environmental Stewardship Program in 2007.

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. Please check all that apply.

Press Releases, Bulletin Board, Web Site
URL: http://No current web site.

OMB No. 2010-0032
SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION FOR ANNUAL PERFORMANCE REPORT
The U.S. Environmental Protection Agency is not yet in a position to accept electronic signatures and therefore requests a faxed, signed copy of the Section E page. Please complete Section E online, then print Section E using the link on the Overview page. Section E should be signed by the senior manager of your facility and faxed it to the Performance Track Information Center at (617) 354-0463.
On behalf of Karl Schmidt Unisia, Inc. Fort Wayne Facility, I certify that: I have read and agree to the terms and conditions as specified in the National Enviromental Performance Track Program Guide. This facility, to the best of my knowledge, continues to meet all program criteria; I have personally examined and am familiar with the information contained in this Annual Performance Report. The information contained in this report is, to the best of my knowledge and based on reasonable inquiry, true, accurate, and complete; My facility has an environmental management system (EMS), as defined in the Performance Track EMS criteria, including systems to maintain compliance with all applicable federal, state, tribal, and local environmental requirements, in place at the facility, and the EMS will be maintained for the duration of the facility's participation in the program; My facility has conducted an objective assessment of its compliance with all applicable federal, state, tribal, and local environmental requirements; and the facility has corrected all identified instances of potential or actual noncompliance; and Based on the foregoing compliance assessments and subsequent corrective actions (if any were necessary), my facility is, to the best of my knowledge and based on reasonable inquiry, currently in compliance with applicable federal, state, tribal, and local environmental requirements. I agree that EPA's decision whether to accept participants into or remove them from the National Environment Performance Track is wholly discretionary, and I waive any right that may exist under any law to challenge EPA's acceptance or removal decision. I am the senior manager with responsibility for the facility and am fully authorized to execute this statement on behalf of the corporation or other legal entity whose facility is part of the National Environmental Performance Track program.
Signature/Date:	______________________________________________________
Name:	Mr. Mark Lennart
Title:	Vice President of Operations
Facility Name:	Karl Schmidt Unisia, Inc. Fort Wayne Facility
Facility Street Address:	2425 Coliseum Boulevard South Fort Wayne, IN 46803
Mailing Address:	2425 Coliseum Boulevard South Fort Wayne, IN 46803
Performance Track ID#:	A050086

Goal 3: Karl Schmidt Unisia, Inc. Fort Wayne Facility's third goal is to reduce the facility's discharges to water of toxics, specifically coolant (Houghton 795).
C.3.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	This goal is complete with at least monthly inspections of this area.
	Activities Conducted During 2006:
	Our goal is to complete this project by the end of 2007. We review and inspect this area at least monthly.
	Activities Conducted During 2005:
	A dedicated closed trailer was sealed inside to prevent leakage of coolant, as the product is put inside. It trailer was sealed in April.
C.3.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	This area of the operation is no longer there. It was related to the loss of the Ford business.
C.3.c	Please report your facility's actual performance.

Goal 4: Karl Schmidt Unisia, Inc. Fort Wayne Facility's fourth goal is to remove PCB-containing capacitors and replace them with non-PCB containing capacitors.
C.4.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	This project is complete.
	Activities Conducted During 2006:
	We have now removed all know PCB capacitors, with the help of the electric company.
	Activities Conducted During 2005:
	Last capacitor containing PCB was removed and replaced with non-PCB containing capacitors at the Fort Wayne Facility by an outside environmental company.
C.4.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	We removed all of the capacitors a few years ago so we have none left on the site to measure/count.
C.4.c	Please report your facility's actual performance.

D.1.a	Please describe your process to identify potential community environmental concerns.
	Informational number established for telephone calls requesting information or submitting complaints regarding the facility. All telephone calls are logged by security, reviewed as they happen, and also reviewed at our yearly management review.
D.1.b	If you identified community environmental concerns, how did you respond to them?
	None were identified. If there were, we would have newspaper submittals, as required by regulatory agencies or other requests. We also inform or keep informed the Harvester Community Association, which is the local association.
D.1.c	Please describe how you informed the community about environmental matters related to your facility.
	We would have newspaper submittals as required by regulatory agencies or other requests. We inform the Harvester Community Association. We informed them of the facility becoming a Charter member of the Indiana Environmental Stewardship Program in 2007.
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. Please check all that apply.
	Press Releases, Bulletin Board, Web Site
	URL: http://No current web site.

SECTION A: GENERAL FACILITY INFORMATION

SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION FOR ANNUAL PERFORMANCE REPORT