Workshop D Redevelopment Done Right at Fuyao Glass America in Moraine, Ohio Tuesday, March 21, 2017 9:45 a.m. to 11 a.m .
Biographical Information John Crane, EHS Manager, Fuyao Glass America 2801 W Stroop Rd. Moraine, OH 45439 (937) 496-5777 JCrane@fuyaousa.com John began his career serving our country with the US Air Force in 1986, where he utilized his Bioenvironmental Engineering experience to handle industrial hygiene (air, water, and environmental sampling) surveillance and manage a drinking water monitoring programs. John was an Instructor for the Defense Medical Readiness Training Institute in Ft. Sam Houston, Texas. John has served in two deployments, Operation Desert Storm/Shield and Operation Freedom in Iraq. From 2004-2007 John was the Chief Special Surveillance at Wright-Patterson AFB, Ohio. John served as the Chief of Chemical and Biological systems safety for the Air Force Operational Test and Evaluation Center (AFOTEC) of the Kirtland Air Force Base in New Mexico from 2007- 2010. After John’s successful career with the US Air Force, he became a Compliance Officer for the US Department of Labor, Occupational Safety and Health Administration (OSHA), Manhattan and Cincinnati Area Offices in 2010. John’s role at OSHA included being a member of the regional rapid response teams. John’s role focused on evaluating corporate health and safety programs at both construction and industrial manufacturing locations, to ensure compliance with federal standards. John joined Fuyao Glass America in April 2016 as the Manager of Environmental, Health and Safety. John’s primary responsibility is to develop and implement safety and environmental programs for Fuyoa’s Moraine facility. John leads international teams in building cross-cultural safety programs. John role includes leading all the EHS teams, both internal staff and external contractors, towards the implementation of Fuyao’s EHS programs. John is also responsible for ensuring Fuyao satisfies customer quality and environmental requirements. John is a graduate of Columbia Southern University with a B.S. Occupational Safety and Health. John is also a graduate of the US Air Force with a degree in Bioenvironmental Engineering Technology.
Biographical Information Jodi J. Keller, Senior Project Manager, Terracon 611 Lunken Park Drive, Cincinnati, OH 45226 513-612-9038 Jodi.Keller@terracon.com Jodi started her environmental career with the Virginia Department of Environmental Quality (VA DEQ) in Richmond, Virginia as an inspector in the wetland mitigation program. While at VA DEQ, Jodi progressed to an Environmental Engineer position with the Harrisonburg Office in the Air Permitting Division. Jodi’s role with the VA DEQ was to review air permit applications and annual emission reports, issue air permits, and conduct compliance inspections for various industrial manufacturing facilities across 14 counties of Virginia. In 2004, Jodi moved to the Cincinnati area to join Environmental Resources Management, Inc. (ERM) and began her career as an environmental consultant. Jodi’s role as a consultant at ERM expanded her professional experience beyond air permitting and into other environmental and health & safety regulatory compliance areas, including compliance audits, permit applications and environmental program development for industrial and telecommunication clients. While at ERM, Jodi served as the Branch Manager for the Cincinnati Office, managing approximately 20 employees. Jodi joined Terracon in September of 2014 as a Senior Project Manager in efforts to grow Terracon’s Regulatory Compliance services within the Eastern Midwest Operating Group. With over 12 years of environmental consulting experience, Jodi’s role at Terracon focuses on regulatory compliance project management and quality assurance. Jodi serves as the Chair of Terracon’s Regulatory Compliance Practice Resource Group (PRG) and is a Terracon Authorized Project Reviewer (APR). Jodi is a graduate of Eastern Michigan University with a B.S. In Biology and received an MBA from Xavier University in Cincinnati, Ohio.
Redevelopment Done Right at Fuyao Glass America 2017 MEC Annual S&EHS Symposium Session D March 21, 2017
The Challenges of Redevelopment 2017 MEC Annual S&EHS Symposium Session D March 21, 2017
INTRODUCTIONS • John Crane EH&S Manager at Fuyao Moraine Plant • Jodi Keller Sr. Project Manager at Terracon
WHO IS FUYOA? • Worlds largest automotive glass facility • American made auto glass. International Reputation. • Chinese based ownership • Founded in 1987
The Fuyao customer roster reads like a who’s who in the automotive industry
NOT NEW TO THE USA • Mt. Zion, IL – Purchased in 2014 – Previously known as the PPG Mt. Zion factory – Upgraded and reconstructed to include additional float glass lines – Supplies Moraine with the raw auto‐glass – Expanding in Decatur, • Greenville , SC – Service Center • Lake Orion, MI – Founded in November 2010 – General warehousing and glass manufacturing – Expanding in Plymouth
FUYAO PRODUCTS
MORANIE OPERATIONS • Late 2014 Purchased & Redevelopment • 2016 Grand Opening • Automotive Glass Processing Facility • Original Equipment Manufacturing (OEM) ‐ Hold over 300+ patents • Automotive Replacement Glass (ARG)
MORANIE OPERATIONS • Autoclaves • Printing • Grinding • Laminating • Cutting • Tempering • Bending • Recycling Glass • Etching • Packaging
HISTORY OF PROPERTY • Old GM Truck Assembly Plant, fully closed in 2008 – Loss of more than 2,400 jobs – More than 2.5 MM sq.ft. of manufacturing space vacant – Over 200 acers of property • Frigidaire appliance plant from 1951 to 1979 • Industrial Reality Group (IRG) redevelopment ownership
ORIGINAL MORAINE PLAN • 1.4 million square • $230 million planned investment • Create 800 jobs on in 5 years • Largest Chinese automotive investment in the United States
DEVELOPMENT PARTNERS + Created 100’s of subcontractor jobs in the area
DEVELOPMENT CHALLENGES “Some of the challenges, we’re taking a manufacturing plant, an assembly plant that’s been setting idle for over seven years and now making it into a world class automotive glass facility,” said Mike Stanoikovich, Woolpert senior V.P.
CONSTRUCTION CHALLENGES • Long industrial history • Convenient and restrictions • Largest energy consumption client in region • Availability of all utilities
CURRENT STATUS • Current glass production is 4M OEM & 4M ARG annually • New facility entrance • Onsite restaurant • $1M warehouse addition
EH&S APPPLICABILITY Multiple OSHA Regulations Apply: Multiple Environmental Regulations Apply: • PPE • Air permits • Walking working surfaces • Water permits • Machine guarding • EPCRA • Electrical • SPCC • Exit routes • RCRA • Chemical safety
TOP H&S CHALLENGES 1.Cultural Difference 2.Communication 3.Program Development 4.Working & Construction Zones 5.Contractor Management
H&S CHALLENGE #1 Cultural Differences ‐ Chinese worker ‐ American worker ‐ 8+ years of displaced work force in area
H&S CHALLENGE #2 Communication ‐ Language barrier ‐ Not just translation ‐ Start‐up speed ‐ Constant changes
H&S CHALLENGE #3 Program Development – Ensuring correct PPE – Designing effective machine guarding – Written SOPs – Training
H&S CHALLENGE #4 Management of active manufacturing environmental combined with construction zones
H&S CHALLENGE #5 Contractor Management • Multiple construction firms • Service professionals • Staffing company • Safety equipment supplier
THE ROAD TO TODAY It hasn’t been easy….. • 8 OSHA inspections & 6 with violations • Several management & staff changes • Continuous steps to improvement • Dedicated to growing in the right direction
TOP ENVIRONMENTAL CHALLENGES 1.Process Confidentiality 2.Communication 3.Roles & Responsibility 4.Process Changes 5.Permitting Changes
ENVIRONMENTAL CHALLENGE #1 Process Confidentially
ENVIRONMENTAL CHALLENGE #2 Communication • Translation • Between contractors • Between internal departments • Agencies
ENVIRONMENTAL CHALLENGE #3 Roles & Responsibilities • Timing vs. production • Fast ramp up • New environmental management • Changes to facility management • Multiple consultants
ENVIRONMENTAL CHALLENGE #4 Process Changes • Exceeded initial plans • Speed of construction • Additional equipment • Increased production • Continuous process improvements
ENVIRONMENTAL CHALLENGE #5 Permitting Changes • Additional equipment • Changes to equipment • Chemical process updates • Reuse of existing equipment – Emergency generators – Fire pumps
THE ROAD TO TODAY • It hasn’t been easy….. • 2 NOVs from MCES • 1 NOVs from OEPA • Environmental reporting • Continuously monitoring • Process improvements • Plan development
KEYS TO OVERCOMING THE CHALLENGES • Lots of meetings….can’t over communicate • Open & continued discussions with regulators • Educating each other • Team work
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