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NPEP Success Story: Federal-Mogul: Driveline
Federal-Mogul: Driveline Products Eliminates Over 24,000 Pounds of Lead
Federal-Mogul is a global supplier of automotive components, modules, and systems serving the world's original equipment manufacturers and the aftermarket industry. The company utilizes its engineering and materials expertise, proprietary technology, manufacturing skill, distribution flexibility, and marketing power to deliver quality products and services and leading brands. Federal-Mogul is focused on driving global profitable growth and creating value to satisfy customer, employee and stakeholder expectations.
Federal-Mogul was founded in Detroit in 1899. Headquartered
in Southfield, Michigan, the company, which reported
sales of $6.3 billion in 2005, employs 42,000 people
worldwide. The Company's principal customers include
many of the world's foremost original equipment
manufacturers of automotive, light commercial, heavy-duty
truck, agricultural, marine, rail, and industrial
vehicles and equipment as well as the worldwide
aftermarket. Federal-Mogul's products are sold under
a variety of power brands, including but not limited
to, AE® engine products, ANCO® wipers, Champion®
spark plugs and wipers, Fel-Pro® gaskets, Ferodo®
brake pads, Glyco® bearings, Goetze® piston
rings, Moog® chassis products, National®
wheel-end components, Nüral® pistons, Payen®
gaskets, Sealed Power® engine products, and
Wagner® lighting and brake products.
Federal Mogul's NPEP Goals
Driveline Products decided to eliminate lead as
a component of its bearing cups used in the manufacture
of universal joints for auto, truck, and agricultural
equipment. Federal Mogul set two NPEP goals. The
first goal was to reduce lead by 75% (18,677 pounds)
by December, 2005 and the second was to reduce lead
by another 10% (623 pounds) by December, 2006.
NPEP Project Implementation
Material substitution was our primary method
of eliminating lead. Switching to calcium based
bearing cups required re-tooling of the screw machines
involved in the machining process. Operators, engineers,
and toolroom and maintenance technicians, as well
as an oil supply vendor, were instrumental in the
success of this project.
Hurdles Faced
Two major hurdles the lead-free team had to
overcome were higher tool costs and poor quality
parts. The lead-free team employed many new tooling
concepts such as tooling coatings along with new
lubricating ideas before success was realized.
Waste Minimization Results
We exceeded our goals. Using a baseline year of
2004 and 24,903 pounds of lead, Driveline Products
exceeded the 2005 reduction of 75% and the 2006
reduction of 10% and is now using 100% lead-free
bearing cups for a total reduction of 24,903 pounds
of lead.