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Sub-Sectoral Environmental and Social Guidelines: Motor Vehicle Assembly
Sub-Sectoral Environmental and Social Guidelines: Motor Vehicle Assembly
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Guidelines: Motor Vehicle Assembly
There are close linkages with other metal Most vehicle manufacturing facilities are more
industry sectors, particularly Foundries, Metal accurately described as assembly plants as they
Surface Engineering, and Metal Fabrication (see now confine themselves to producing body
separate Guidelines), as well as to the parts, machining the engine, final assembly and
manufacture of plastic products, glass and painting. All other parts are typically bought in
textiles. It is common for the Press Shop and on a “just-in-time” basis, e.g. castings/forgings,
Metal Surface Engineering (Plating Shop) to be electrical/electronic equipment, wheels/tyres,
located on the same site and in these cases, it instruments etc. Approximately 8,000 to 10,000
will be necessary to refer also to the relevant parts are assembled into approximately 100
guidelines. major vehicle components 1 . Assembly plants are
highly automated computer controlled assembly
The vehicle manufacturing process is shown in line operations.
the diagram below.
The unpainted vehicle body (also known as the
“body-in-white”) is assembled from formed
body panels joined by welding, glued and
riveting. The vehicle passes by conveyor to the
paint shop for:
1 US EPA 1995
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Guidelines: Motor Vehicle Assembly
The Soft Trim is the fitting of seats, door pads VOCs emissions are reduced through:
and upholstery.
• Source control (e.g. the use of powder paints
The vehicle is then fitted with the petrol tank, or low VOC/high solids water-based
exhaust, and bumpers. At the same time, the coatings),
engine is assembled. The engine and tyres are
then fitted and the vehicle is subjected to a • An increase of transfer efficiency of the
rigorous inspection. application technique,
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Guidelines: Motor Vehicle Assembly
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Guidelines: Motor Vehicle Assembly
may cause asthma. Other curing agents may OTHER ENVIRONMENTAL, HEALTH
damage genetic material, which could cause AND SAFETY RISK/LIABILITY ISSUES
some diseases including cancer and impaired
fertility. Energy Consumption
Various organic solvents are used in degreasing. Motor vehicle assembly plants use energy
The most commonly used are chlorinated throughout the plants for many different end-
solvents such as trichloroethylene, uses. The main energy types used on-site are
dichloromethane (methylene chloride) and electricity, steam, gas and compressed air.
perchloroethylene. These substances may be
harmful to health if inhaled. The ill-health Paint shops are the major energy-consuming
effects from inhalation would depend on the centre. Energy is used to condition the air for
substance in use and the concentration and the painting and drying steps, as well as for the
length of exposure. At high concentrations all drying process and for treatment of the
organic solvents exert a strong narcotic effect emissions and for ventilation.
and can be fatal. Skin exposure can cause
irritation and dermatitis. Noise and Vibration
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Guidelines: Motor Vehicle Assembly
Particular attention should be given to buildings • Cover or otherwise protect sharp edges;
constructed before the 1980s.
• Use personal protective equipment.
Machinery/Product Handling
Collision
Injuries resulting from the manual handling of
objects and materials with sharp edges and from Heavy loads are lifted and moved at elevated
entanglement and entrapment in the moving heights using hydraulic platforms and cranes
parts of machinery are common in the presenting a serious safety hazard.
engineering industry, particularly
Manual Handling and Repetitive Work
• Where people are involved in handling sheet
or strip metal; Lifting, repetitive work, poor posture and
carrying heavy or awkwardly shaped objects,
• During work at presses, where small pieces such as large parts and heavy equipment can
of metal with sharp edges are handled result in injuries.
frequently;
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Slips, Trips and Falls significant part of, the costs of the
implementation of this measure and/or take
These often occur on the same level and are back end-of life vehicles.
primarily caused by uneven surfaces,
inappropriate footwear, lighting and trailing OTHER SOCIAL, LABOUR AND
cables especially during maintenance and COMMUNITY RISK/LIABILITY ISSUES
cleaning activities.
Dust and Odours
KEY SOCIAL, LABOUR AND
COMMUNITY RISK/LIABILITY ISSUES Public/environmental health and nuisance issues
associated with dust and vented fumes can arise
Supply Chain from production activities and may have a
significant effect on neighbouring locations.
The environmental and social impact of vehicle This may be important if there are neighbouring
manufacturing companies is heavily dependent residential and industrial activities in the area;
on the performance of companies within their
supply chain as the majority of components are Transport
bought in either from external suppliers or
subsidiaries. Transport of products by road can be a
significant issue. This might lead to road noise
Likewise, most manufacturers operate on a and traffic congestion.
“just-in-time” basis and a sudden reduction or
increase in production can have serious FINANCIAL IMPLICATIONS
economic consequences for suppliers.
• The last holder of an end-of-life vehicle in
Vehicle Use the EU may dispose of it free of charge
("free take-back" principle). Producers must
The use of motor vehicles is responsible for meet all, or a significant proportion of, the
greenhouse gas emissions from the combustion cost of this measure.
of fossil fuels. Many national governments have
imposed fiscal and legislative measures to reduce • Many countries are signatories to the Kyoto
the emissions from motor vehicles. Significant Protocol and have adopted targets for the
investment will continue to be required to reduction of CO2 emissions. Where
improve engine efficiency or to develop Governments have set up carbon emission
alternative fuels/power sources. reduction programmes industrial processes
have been required to reduce their CO2
End of Life Vehicles emissions through the setting of targets.
This can result in a need for substantial
Under the EU End of Live Vehicles (ELV) investment in new/clean technologies to
Directive 200/53/EC, vehicle producers must achieve the emission targets. These targets
set up systems for the collection of all end-of life may be reflected in environmental permits.;
vehicles and, as far as technically feasible, of
waste used parts removed when passenger cars
are repaired. They must also meet all, or a
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• Injuries may lead to increased payroll costs to • Install or upgrade of abatement technology
replace skilled workers and lost production to minimise exposure to hazardous
time; substances and to control the release of
emissions, e.g. enclosure of equipment, use
• Capital investment may be required to of appropriate ventilation with filters, gas
comply with new environmental, health and balancing systems, cyclones, and wet or alkali
safety requirements; scrubbers
• Fines, penalties and third party claims may be Noise & Vibration
incurred for non-compliance with
environment, health and safety regulations. • Enclose noisy machines to isolate people
from the noise where practicable;
IMPROVEMENTS
• Reduction of exposure times for people
Environmental, Health and Safety working near noisy machinery and provide
Improvements personal protective equipment where people
have to enter noisy areas;
General
Water and Wastewater
• Environment, health and safety training for
all employees and contractors; • Consider feasibility of substitution of
hazardous chemicals such as solvent based
• Good housekeeping should be maintained at paints with less hazardous alternatives;
all times in all areas to reduce the likelihood
of incidents and accidents; • Consider upgrades to wastewater treatment
facilities;
• Systems should be subject to frequent and
proper inspection; • Recycle treated wastewater where possible
back to the processes or to secondary uses
• Routine plant maintenance to keep small such as for cleaning;
leaks and spills to a minimum and maintain
plant efficiency; • Maintain on site abatement equipment and
wastewater treatment plant.
• Controls should be implemented to minimise
the exposure to gases, fume, dust, noise and Storage
vibration.
• Bulk containment must be:
Airborne Emissions
o Inspected regularly to prevent leakage;
• Implement a Solvent Management Plan to
monitor and control the use of solvents on o Provided with secondary spill
the site; containment;
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o Installed with automatic alarms and shut o Install walkways and signage to separate
off systems. people from vehicle movements to reduce
risk of collision.
Waste
• Route cables and pipework under walkways
• Return empty containers to the supplier for to prevent slips, trips and falls;
reuse.
• Construct walkways of non slip materials;
Energy Efficiency
• Provide the local fire department with a list
• Improve insulation to minimise heat loss; and volume of products stored on the
premises.
• Potentially use heat and energy recovery
techniques, such as steam rising boilers to Social Community and Labour
capture hot gases and re-use elsewhere in Improvements
operation or for generating energy.
• Implement a grievance/dispute resolution
Health & Safety mechanism for workers and members of the
community to raise issues with the Company.
• Provision of personal protective equipment
(PPE) that is fit for the task to prevent injury. GUIDE TO INITIAL DUE DILIGENCE
Staff should be trained in the correct SITE VISITS
selection, use and maintenance of PPE;
During the initial site visit, the issues will vary
• Redesign manual processes to avoid heavy according to the type of process being used and
lifting/repetitive activities; product being produced and depending on the
level of environment, health and safety
• Install mechanical lifting aids where possible management already introduced.
and rotate work tasks to reduce repetitive
activities; General
• Separate people from vehicles and machinery • Confirm organisational responsibilities and
were practicable: systems for environment, health, safety and
social matters; Confirm that these apply to
o Ensure that the process layout reduces all employees and sub contractors.
opportunities for process activities to
cross paths; • Note signs of poor housekeeping, such as
signs of spillages and high numbers of empty
o Installation of safeguards on moving parts or partially filled drums. Note the condition
of conveyor belts to reduce risk of of the drums. Particularly note any recent
entrapment of employees; spills.
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systems are in place to monitor and maintain without adequate treatment prior to
physical assets? What investment in asset discharge;
management is planned? Look for wear and
tear and poor maintenance. • Is the water quality tested? What are the
waters tested for? Where are the samples
Air Emissions Management taken from, how often? Do the discharges
have to meet set standards?
• Are there any fume control measures? Do
these work and are these used? Is there any Solid Waste Management
build-up of dust on machinery or other
surfaces? • Note nature of solid waste disposal;
• What does the quality of these discharges • What fuels and materials are stored in bulk
look like? Note the colour and appearance on site?
of adjacent watercourses;
• To gauge the potential for spillages and leaks
• Note whether the wastewater treatment plant consider the following:
discharges to ground, a local watercourse or
the municipal wastewater treatment works. o Are there any underground storage tanks?
Higher environmental risks will be associated
with facilities discharging to water courses
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o Are surface storage tanks and usage areas Inspections & Regulation
hard surfaced and bunded? Are these in
good condition or are cracks present? Are • Check the conditions and duration of validity
these regularly tested for leakages? for all permits;
o Is the size of the bunding adequate for • What systems are in place to check and
the volume of the materials stored? maintain assets and infrastructure?
o Are the bunds regularly cleaned out to • Have the premises been inspected recently by
avoid loss of capacity due to holding the regulatory authorities for health, hygiene
rainwater etc.? and environment? What were their findings?
• Is fire fighting and first aid equipment • Review budgets for capital expenditure
available? Is there a trained and competent (capex) and operational expenditure to cover
fire fighting resource on site? environment, health and safety matters.
Does the business plan have line items for
• Have there been any recent (within the last environment, health, safety and social
three years) incidents on site such as improvements as well as asset management
fatalities, fires/explosions, spills? and maintenance?
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these been considered and assessed by the include in the action plan. As a minimum, any
company? business should be required to have the
following in place:
• If the company plans to invest in new
technology, what will be the impacts and Environmental, Health and Safety
benefits for human resources?
• Operational procedures to manage
Social, Labour and Community environmental, health, safety and social risks;
• Does the organisation have a grievance • Waste management plan (waste minimisation,
mechanism which allows employees to raise re-use, recycling, monitoring);
workplace concerns?
• Senior management review/demonstrated
• Are employees free to form, or join, a involvement in environment, health, safety
worker’s organisation of their choosing? and hygiene management.
ACTION PLANS
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European Bank for Reconstruction and Development (EBRD). Environmental and Social Policy May
2008. Performance Requirement 2: Labour and Working Conditions.
http://www.ebrd.com/enviro/tools/index.htm
European Union 1999, Council Directive 1999/13/EC of 11 March 1999 on the limitation of emissions
of volatile organic compounds due to the use of organic solvents in certain activities and installations,
http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=CELEX:31999L0013:EN:HTML
European Union 2000, Directive 2000/53/EC of the European Parliament and of the Council of 18
September 2000 on end-of life vehicles - Commission Statements, http://eur-
lex.europa.eu/LexUriServ/LexUriServ.do?uri=CELEX:32000L0053:EN:HTML
European Union 2004, Directive 2004/42/CE of the European Parliament and of the Council of 21 April
2004 on the limitation of emissions of volatile organic compounds due to the use of organic solvents in
certain paints and varnishes and vehicle refinishing products and amending Directive 1999/13/EC,
http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=CELEX:32004L0042:EN:HTML
Galitsky C, Worrell E 2008, Energy Efficiency Improvement and Cost Saving Opportunities for the
Vehicle Assembly Industry: An ENERGY STAR® Guide for Energy and Plant Managers, Environmental
Energy Technologies Division, Ernest Orlando Lawrence Berkeley National Laboratory, Sponsored by
the U.S. Environmental Protection Agency, March 2008,
http://www.energystar.gov/ia/business/industry/LBNL-50939.pdf
Irish Environmental Protection Agency 2005, Best Practice Guidelines for Vehicle Coating & Refinishing,
http://ec.europa.eu/environment/air/pollutants/stationary/solvents/activities/pdf/d058_best_practice_
vehicle_coating.pdf
United Kingdom Department for the Environment, Food and Rural Affairs 2004, Process Guidance Note
6/20(04): Secretary of State's Guidance for Paint Application in Vehicle Manufacturing,
www.defra.gov.uk/environment/ppc/localauth/pubs/guidance/notes/pgnotes/pdf/pg6-20.pdf
United Kingdom Department of the Environment 1995, Engineering Works: Vehicle Manufacturing
Works, http://publications.environment-agency.gov.uk/pdf/SCHO0195BJLI-e-e.pdf?lang=_e
United Nations 2007, Globally Harmonized System of Classification and Labelling of chemicals (GHS),
Second Revised Edition, available at
http://www.unece.org/trans/danger/publi/ghs/ghs_rev02/02files_e.html
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United States Environmental Protection Agency (EPA) 1995, Sector Notebook Project Profile of the
Motor Vehicle Assembly Industry, September 1995
http://www.epa.gov/compliance/resources/publications/assistance/sectors/notebooks/motvehsn.pdf
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