June 5 is World Environment Day sponsored by the United Nations. This observance is celebrated every year and aims to engage governments, businesses, and citizens to address pressing environmental issues. So, I felt it timely to discuss how McWane Inc. and its family of companies worldwide are committed to protecting the environment through proactive efforts and challenging employees to think outside the box.
What Exactly is World Environment Day?
In 1972, the UN General Assembly designated June 5 as World Environment Day (WED). The first celebration, under the slogan "Only One Earth," took place in 1974. In the following years, WED developed as a platform to raise awareness of our environment's problems, such as air pollution, plastic pollution, illegal wildlife trade, sustainable consumption, sea-level increase, and food security. Furthermore, WED helps drive change in consumption patterns and national and international environmental policy.1
“It pushes for individuals to think about the way they consume; for businesses to develop greener models; for farmers and manufacturers to produce more sustainably; for governments to invest in repairing the environment; for educators to inspire students to take action, and for youth to build a greener future.” – WorldEnvrionmentDay.global 2
What is McWane’s Approach Regarding the Environment?
“Our approach to environmental, health and safety (EHS) starts with a clear vision from our leaders, supported by strong policies that place the environment and safety at the core of the business with substantial investments in state-of-the-art technologies and modern infrastructure,” said Jeet Radia, McWane Senior Vice President Environment, Safety & Human Resources.
Our EHS system provides an organized and consistent approach to achieving this goal and assuring continuous improvement. McWane addresses the unique environmental and safety challenges faced by our industry with a comprehensive Environmental, Health and Safety (EHS) management system based on the principles of the International Organization of Standardization (ISO) 14001 standard, Occupational Health and Safety Administration (OSHA) 18001 and OSHA Management Guidelines.
ISO 14001 is an internationally recognized specification for environmental management systems. Our EHS management system allows us to manufacture our products in an environmentally compliant and friendly way and provide communities with a foundation for life with clean, safe, and dependable drinking water.
What is the McWane Pollution Prevention Challenge (P2C)?
The best way to deal with pollution is to prevent it from being created in the first place. This means finding new efficiencies, doing things smarter, and valuing every resource. Each December, the McWane Pollution Prevention Challenge (P2C) brings teams across McWane to have their ideas judged for innovation, simplicity, cost savings, and environmental benefits. Since the inaugural competition in 2011, those ideas have generated millions in company-wide savings. Employees from around the world submit projects focused on areas such as:
- improving recycling
- reducing waste
- reuse opportunities
- pollution control
- energy savings
- improving efficiencies
- and improving our overall environmental impact.
"We want to be great stewards to the community, so the P2C competition certainly allows us to do this," said Tom Crawford, McWane Ductile VP/GM – Ohio Foundry. "It encourages our employees to engage and actually uses their ideas to not only make the company better but provides a better, cleaner environment. I want 500 brains thinking about how we can be better versus just a very few.”
Numerous McWane facilities hold an internal P2C challenge where winners are selected. All entries, whether site-specific winners or not, are submitted to the corporate-wide competition. The company averages more than 30 entries per year, and finalists present their projects before a panel of independent judges. Judges then narrow down the entries to the top three projects.
“The P2C is a competition in the hands of the employees,” said Tom Kistler McWane Ductile-Ohio Assistant Environmental Manager-Poles. “Instead of EHS looking for answers… P2C asks the employees and their leadership for creative ideas to reduce waste, recycle, and reduce raw material input.”
The challenge is conducted over three months to determine if submissions are viable. Specific criteria and variables are monitored while collecting data in areas such as cost savings, waste reduction, energy consumption, and more.
What Are Some Positive Results from the P2C Challenge?
“It’s bottom-up, not necessarily top-down where the best ideas come from,” said Joe Ozimek, McWane Ductile-Utah Environmental Manager. “P2C shows that people are valued. It allows them a good chance to showcase their ideas to make them and their entire departments look good. Along with making a positive impact on their environment, they can get some money in their pocket too!”
The P2C competition has changed the way McWane thinks and has served as the hallmark of efforts toward sustainability and environmental stewardship. To encourage the implementation of more pollution prevention ideas at all McWane facilities, the "Why Didn't I Think of That" Award was also introduced. This category recognizes entries with innovative, low-cost, and straightforward solutions, producing relatively small but significant environmental benefits.
Which P2C Projects Were Standouts?
Tom Crawford is a P2C judge at the Ohio facility. When asked which submissions were standouts and fully implemented, he replied, “One project was waste reduction at the cupola. It used casting shapes to reduce the total refractories used on the runner from the cupola. This project was a safety win as well. It resulted in less pollution, less waste, and less work for employees.”
Crawford also spoke of an individual submission by Jay Fouch, who suggested using metal, reusable timbers instead of wood. “The company spends roughly $750,000 per year on wood timbers that would ultimately get thrown away. We have a prototype of a reusable metal timber that will save thousands of dollars on materials and reduce waste every year,” said Crawford.
Joe Ozimek recalled a project at the Utah foundry; “In pipe finishing, we used to use carpet that was saturated in paint to reduce rail marks created by asphalt coating while also making the pipe look good. Someone suggested we use reusable plastic sheeting instead of carpet. We now use less paint, and we no longer use carpets. This solution equated to saving two 6,000 gallons of paint and two roll-off boxes of carpeting every year.”
“This was a big money-saver, along with increased safety and improved production since we’re no longer required to shut the line down to change the carpet. Such a simple idea had a positive domino effect, right down the line,” said Ozimek.
Recent Pollution Prevention Winners
2020
- First place: Clow Canada
VOC Reduction - Second place: McWane Dutile - Utah
Reuse of Dunnage - Third place: McWane Ductile - Utah
Sand Supplier - "Why Didn't I Think of That" Award: McWane Ductile - Ohio
Butterfly Valve Bonnet - Energy Efficiency (E2) Award: Kennedy Valve
Hydraulic Set-On Unit
2019
- First place: M&H Valve
Pattern Changes - Second place: Clow Canada
Plastic Reduction - Third place (tie): McWane Ductile - Utah
Special Linings Shot Reuse - Third Place (tie): McWane Ductile - Utah
Test Press Pad (Bell Blocks) - "Why Didn't I Think of That" Award: McWane Ductile - Ohio
Blackening Tank Reduction - Energy Efficiency (E2) Award: Clow Valve
Iron Melt Reductions
2018
- First place: AB&I Foundry
Innovative use of cupola as an oxidation device - Second place: Tyler Union
Sand reclamation enhancements - Third place (tie): M&H Valve Company
Replaced sand pig molds with castable pig molds - Third Place (tie): McWane Ductile - Ohio
ISO core machine waste sand reduction - "Why Didn't I Think of That" Award: Anaco/Clow Corona
Non-RCRA Hazardous Waste Bulk Management - Energy Efficiency (E2) Award: Kennedy Valve Company
Dust collection solutions with better pulse valve technology
2017
- First place: McWane Ductile - Ohio
Cupola Bottom Drop - Second place: Amerex
Compressed Air Monitoring - Third place: McWane Ductile - Utah
Bundling Station Paint Mats - "Why Didn't I Think Of That" Award:
Manchester Tank Elkhart - Dry Lubricant Reduction
McWane Ductile - Utah - Wood Dunnage Reduction
2016
- First place: McWane Ductile - Utah
Refractory Consolidation and Controls - Second place: McWane Ductile - Ohio
Reduction of Casting Trough Coating - Third place: Kennedy Valve Company
Core Oven Heat Curtains - "Why Didn't I Think Of That" Award:
Amerex - Reduction of Waste Caused by Spent Rugs
McWane Ductile - Utah - Cupola Spout Refractory Conservation
Clow Canada - D67M Elbow Casting Material Reduction
Applying Innovative Concepts Across the Company
"The judges and competing locations have always been very impressed by the innovative ideas, presentations, and the keen interest and passion shown by the participating team members," said Jeet Radia.
Steve Shambeda, McWane Ductile-New Jersey Engineering Manager, likes reviewing P2C presentations submitted by other plants because everybody is willing to share information. This sharing allows others to take new ideas back to their foundry. “Watching the P2C Presentations, you can see how the ideas were implemented and how they became effective. We can then ask, ‘How can we apply that in our location to benefit us?’” said Shambeda.
How Can You Reduce Your Environmental Impact?
So, as we quickly approach World Environment Day, I ask, “How can we ALL improve our efforts toward reducing pollution, recycling, saving energy, and protecting our seas, lands, and wildlife?” The impressive scope of ideas submitted by team members from across McWane’s facilities has been an inspiration. And although I am not directly involved in the foundry or on the production line, I can look around my own home and office. I see the one-use plastic water bottle I just drank from on my desk, and I know I can start there! Let’s all help protect our environment for generations to come.
Resources
- Geneva Environment Network, “World Environment Day,” Accessed May 28, 2021. https://www.genevaenvironmentnetwork.org/world-environment-day/
- World Environment Day, “About World Environment Day,” Accessed May 28, 2021. https://www.worldenvironmentday.global/
- McWane Inc-For Generations, “Awards and Partnerships,” Accessed June 1, 2021. https://www.mcwane.com/responsibility/awards-partnerships/
Need Assistance with Your Waterworks Project?
If you have any questions regarding your water or wastewater infrastructure project, be sure to reach out to your local McWane Ductile representative. We have team members who've managed small and large water utility systems, served in engineering consulting firms, and bring decades of experience in solving field issues involving pipeline construction and operation. From design to submittal, to installation, we strive to provide education and assistance to water professionals throughout the water and wastewater industry.
