The WAIB meets in Lake Tahoe. Survival of the Fittest The Western Aerosol Information Bureau (WAIB) held its 40th experts with an outstanding job and as crucial in the success of the annual conference in Lake Tahoe, NV on Sept. 9-11. The theme Drive to Zero project. DuPont Building Innovations is committed to focused on “Survival of the fittest & the aerosol can: How social/ ongoing zero landfill operations. cultural changes will map our future.” Pat Wade of WD-40 Co. Jerry Bialko, Operations Manager, Cobra Plastics, presented served as Master of Ceremonies. Changing the Culture: Personal Accountability & Empowerment. Esther Rosenberg, DuPont, presented Drive to Zero Landfill: A Initially, the culture at Cobra Plastics was Sustainability Journey. DuPont’s core values include safety and “It’s a good place to work; the Quality health, environmental stewardship, high ethical behavior and department is responsible for quality; respect for people, with accountability to all stakeholders. DuPont’s just worry about what happens in your mission is sustainable growth, “the creation of shareholder and department; just worry about what societal value while we reduce the happens on your shift; I’m not doing environmental footprint along the value anything unless the front office says it’s chains in which we operate.” OK.” In 2008, DuPont sent 81 million pounds To start the journey of change, a of manufacturing by-products to a landfill. company must have upper management This represents 16,200 average cars, 1,013 support and involvement, said Bialko. loaded tractor trailers and18 loaded space Pick one process and stick with it and shuttles at launch. The goal was to have Bialko keep it simple: Communicate–Train– zero landfill globally by 2012. By not just Test–Retrain. Avoid the temptation to try reducing landfill, but eliminating it, the “the flavor of the month.” business’s work to reduce its environmental Eventually, Cobra Plastics selected The “Oz Principle” tool to footprint creates a new industry standard facilitate changing the culture in its organization, which includes Rosenberg for environmental stewardship. training for all levels of the organization. Participants must be Why? To reduce DuPont’s environmental willing to “Trust the Process,” hear the “Hard Things” and realize footprint, generate cash and avoid costs, liberate space and because that focused feedback helps them to see “reality” and improve DuPont customers were asking for this. communications. DuPont utilized a Global Six Sigma project covering 15 locations “Above the Line” behavior means constantly asking “What Else which included all manufacturing sites and 3rd parties where Can I Do?” as well as taking ownership, personal accountability DuPont was responsible for the waste. The project was conducted and problem solving. “Below the Line” behavior means playing in two phases: Phase 1 (2008–2010) 40% landfill reduction by the blame game, finger pointing and feeling like a victim. Reasons 12/31/10 and Phase 2 (2011) achieve zero run rate by 12/31/11. become excuses when we stop looking for solutions, said Bialko. Scrap sheet and trim were ground back into first-grade products Multiple initiatives resulted in increased or ground into rock; carrier film was recycled into glue; metal was sales and productivity, even during a tough melted down and recast; banding was melted and recast into same; economic downturn. Cobra attributes its pallets were repaired and repurposed; scrap wood was ground into success to the teamwork of its employees, animal bedding; paper and cardboard were recycled into same; who take great pride in their achievements shrink wrap was recycled into same; sanding waste was used as and “What else can I do?” has become a filler replacement in concrete; Butyl was recycled into energy; the company motto. The key message is DuPont Tyvek trim was recycled into first-grade material; and accountability. contractor waste was sorted and recycled based on the stream. Karina Lutzy, Sexy Hair Concepts, Reaching zero landfill status globally was successfully achieved presented Changes in Hair Styles & Hair in three years. It was a complicated project with high execution Products. The latest hair style and products requirements, and Rosenberg credited the global teams of Six Sigma trends are versatility, fun, easy application Lutzy 40 SPRAY November 2012
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