Global ecologic™ Report - Crown Equipment Corporation
Global ecologic™ Report - Crown Equipment Corporation
Global ecologic™ Report - Crown Equipment Corporation
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
2012<br />
<strong>Global</strong> ecologic <strong>Report</strong>
crown.com<br />
A<br />
our message of sustainability<br />
s a global company, <strong>Crown</strong> manufactures our lift trucks in the communities where we<br />
live and as a result, we respect the environment in all of our operations. We listen to our<br />
customers, our employees and our communities to develop lift trucks and technologies that<br />
are sustainable and that last—a long time. When you select a <strong>Crown</strong> lift truck, you can be<br />
confi dent it has been manufactured with minimal waste and designed for exceptional energy<br />
effi ciency. Take a look at the news today and you’ll see that sustainability and energy effi ciency<br />
are key words that matter not only in business meetings, but also during family dinners.<br />
Every day we fi nd more customers interested in our global sustainability eff orts and processes<br />
and how we diff er from competitors. We focus on sustainability beginning at the<br />
conceptual stage of design through the product’s end of useful life. Product design is one<br />
of the most important steps for infl uencing sustainability. Decisions during this stage<br />
have a widespread eff ect on a product’s life cycle, including end of life management. We<br />
continue to grow in our sustainability eff orts through life cycle thinking. This activity<br />
gives us the knowledge to assess, improve and manage our products and services.<br />
I want to thank our diverse, global team of employees for helping us grow in our sustainability<br />
eff orts. Employees are excited when their sustainability idea comes to fruition and<br />
it becomes a corporate-wide initiative. For example, employees in our electronics facility<br />
have not only achieved zero landfi ll status, but they continue to fi nd even more ways to<br />
reduce and recycle.<br />
We have a lot to talk about when it comes to the future and we enjoy helping customers<br />
make their facilities sustainable, as it’s smart business. For instance, our RM 6000 reach<br />
truck’s regenerative lowering feature puts energy back into the battery as the mast is<br />
lowered and off ers an optional battery that provides longer run time.<br />
We are committed to continually improving our sustainability eff orts and we welcome<br />
your comments and suggestions. As we evolve globally, we’ll continue to collaborate with<br />
colleagues around the world to become more sustainable.<br />
Sincerely,<br />
Jim Dicke III<br />
President, <strong>Crown</strong> <strong>Equipment</strong> <strong>Corporation</strong><br />
Jim Dicke III<br />
President,<br />
<strong>Crown</strong> <strong>Equipment</strong> <strong>Corporation</strong><br />
The <strong>Crown</strong> ecologic brand<br />
represents <strong>Crown</strong>’s commitment<br />
to a clean environment<br />
and smart business through<br />
product development and<br />
manufacturing processes<br />
that minimize waste, manage<br />
energy and maximize lifespan—<br />
a lifespan signifi cantly longer<br />
than industry averages—while<br />
creating products that optimize<br />
productivity.<br />
1
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
table of contents<br />
Corporate Profi le ....................................................................................................................... .................. 3<br />
Our Commitment to Sustainability .......................................................................................... .................. 4<br />
• <strong>Global</strong> Sustainability Groups<br />
• <strong>Crown</strong> ecologic<br />
Our Heritage of Sustainability .................................................................................................. .................. 6<br />
• Sustainable Land Use<br />
• Environmental Policy Statement<br />
Strategic Approach to Sustainability ....................................................................................... .................. 8<br />
• Sustainable Product Development<br />
• Sustainable Integrated Manufacturing<br />
• Our Commitment to Customers<br />
Sustainable Product Development .......................................................................................... .................. 9<br />
• Life Cycle Assessment<br />
• Product Focus<br />
- Longer Life, Less Replacement Parts<br />
- Energy Effi ciency<br />
- Fuel Effi ciency<br />
- Less Waste, Less Space<br />
Sustainable Integrated Manufacturing .................................................................................. ................ 15<br />
• Mast Component Cell Increases Effi ciency, Reduces Fuel Cost<br />
• Employee Commitment to Sustainability<br />
Commitment to Customers .................................................................................................... ................ 18<br />
• Innovative Technology<br />
• Encore Renewed Lift Trucks<br />
- Encore Success in Latin America<br />
• Fuel Cells<br />
2011 Accomplishments ........................................................................................................... ................ 21<br />
Safety and Health .................................................................................................................... ................ 27<br />
Awards and Recognitions ....................................................................................................... ................ 29<br />
Supplemental Information ...................................................................................................... ................ 30<br />
2
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
A<br />
corporate profi le<br />
s a privately held, family-owned business, <strong>Crown</strong> <strong>Equipment</strong> <strong>Corporation</strong> is one of the<br />
world’s largest forklift manufacturers. <strong>Crown</strong> designs, manufactures, distributes, services<br />
and supports material handling products that provide customers with superior value.<br />
Our award-winning line of lift trucks maintains a reputation for exceptional product design,<br />
engineering, manufacturing and sustainability. From the smallest hand pallet truck to<br />
the highest-lifting turret truck, <strong>Crown</strong> seeks to provide our global customers with safe,<br />
effi cient and ergonomic lift trucks that increase productivity.<br />
Headquartered in New Bremen, Ohio, <strong>Crown</strong> manufactures lift trucks that are sold<br />
throughout the world. A strong and extensive global dealer network provides a wide variety<br />
of quality material handling equipment, storage solutions, fl eet management technology<br />
and support services. Our global retail network extends throughout the Americas, Europe,<br />
the Middle East, Africa and the Asia-Pacifi c regions. <strong>Crown</strong> operates 16 manufacturing<br />
facilities in 11 global locations.<br />
Corporate Locations:<br />
• New Bremen, Ohio<br />
• Munich, Germany<br />
• Suzhou, China<br />
• Sydney, Australia<br />
• Singapore<br />
Manufacturing Locations:<br />
• Greencastle, Indiana<br />
• New Castle, Indiana<br />
• Kinston, North Carolina<br />
• Minster, Ohio<br />
• New Bremen, Ohio<br />
• New Knoxville, Ohio<br />
• Celina, Ohio<br />
• Fort Loramie, Ohio<br />
• Roding, Germany<br />
• Querétaro, Mexico<br />
• Suzhou, China<br />
3
table of contents<br />
corporate profi le<br />
commitment to<br />
sustainability<br />
• global sustainability<br />
groups<br />
• <strong>Crown</strong> ecologic<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
C<br />
our commitment to sustainability<br />
rown knows that it is important to take care of our customers, our employees and the<br />
world we live in. At <strong>Crown</strong>, sustainability is integrated into our day-to-day business<br />
processes and our global business strategy. Our commitment to sustainability is evident<br />
in our product development and manufacturing processes and we are committed to help<br />
customers become more sustainable.<br />
This ecologic <strong>Report</strong> features an overview of <strong>Crown</strong>’s sustainability and conservation efforts<br />
for the year, as well as an up-to-date account of our environmental accomplishments. These<br />
facts and figures represent the tangible results of our achievements over the past year, which<br />
illustrate how <strong>Crown</strong> has created a business model that is both sensible and sustainable. In<br />
addition, we have incorporated stories throughout the report that highlight <strong>Crown</strong>’s global<br />
accomplishments.<br />
Sustainability has been a way of life at <strong>Crown</strong> <strong>Equipment</strong> for decades. In a conscious<br />
effort to improve the environment and benefit our customers, <strong>Crown</strong> has spent<br />
countless hours exploring and implementing conservation-minded practices—the<br />
foremost of which is the design, engineering and manufacturing of efficient,<br />
long-lasting lift trucks.<br />
To effectively compete in a global marketplace, we work hard to attract and retain a<br />
diverse team of talented individuals. A diverse work environment gives our employees<br />
opportunities to innovate and create products that best meet the needs of our global<br />
market, and to apply <strong>Crown</strong>’s principles of sustainability in their daily work.<br />
global sustainability groups<br />
To continually improve our global environmental efforts, <strong>Crown</strong>’s international operations<br />
have developed sustainability committees. Facilities in the U.S., Mexico and Germany have<br />
developed these groups to strategically review operations, process and product lines in an<br />
effort to improve on our product's long life, reduction in energy use and improved process<br />
management. These committees meet regularly to discuss projects and opportunities within<br />
their facilities and to share best practices with all <strong>Crown</strong> facilities worldwide.<br />
Overall, <strong>Crown</strong>’s culture inspires employees to consider how they can contribute to our<br />
sustainable eff orts in all facets of the development and manufacturing process.<br />
<strong>Crown</strong> Manufacturing Facility<br />
Querétaro, Mexico<br />
4
table of contents<br />
corporate profi le<br />
commitment to<br />
sustainability<br />
• global sustainability<br />
groups<br />
• <strong>Crown</strong> ecologic<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
<strong>Crown</strong> ecologic <br />
Our commitment to environmental stewardship and sustainability began decades ago<br />
with a focus on processes aimed at reducing our environmental impact. Founded on<br />
the principles of minimizing waste, managing energy and maximizing lifespan,<br />
<strong>Crown</strong> ecologic represents the synthesis of our sustainability eff orts, including<br />
materials recycling and recovery methods, innovative production and lift truck<br />
remanufacturing practices, industry-leading forklift energy effi ciency and the<br />
preservation of land and natural resources. Though notable, these are just some<br />
of the ways <strong>Crown</strong> has made environmental stewardship an everyday part of our<br />
company culture. As a company driven by a strong set of values, we know that<br />
every decision we make has an impact on our world. Therefore, our sustainability<br />
goals continue to evolve globally, and we are continually seeking more ways to be<br />
environmentally responsible.<br />
5
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
• sustainable land use<br />
• environmental policy<br />
statement<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
C<br />
our heritage of sustainability<br />
rown’s record of sustainability is comprehensive, as we have worked hard to conserve<br />
and renew whenever possible—a heritage we will continue to draw upon in future<br />
ecologic enterprises.<br />
sustainable land use<br />
<strong>Crown</strong> strives to conserve and renew resources whenever possible, even when it comes<br />
to housing its offi ces and manufacturing facilities. As we expand, we view each growth<br />
opportunity as a new way to integrate sustainability best practices with the latest, cleanest<br />
and most effi cient technology. Over the years, our sustainability program has included<br />
repurposing many abandoned brownfi eld sites—approximately 2.8 million square feet—<br />
and this eff ort continues with our latest expansion and brownfi eld development.<br />
Our utilization of brownfi eld sites continues with the recent purchase of a vacant<br />
937,000-square-foot former manufacturing plant in New Castle, Indiana that sits<br />
on 83 acres. This facility will house <strong>Crown</strong>’s deep-draw press operation and MoveMore<br />
division. After attending to environmental concerns and remediating areas of the property,<br />
<strong>Crown</strong> used innovative sustainability principles to guide the refurbishment process at the<br />
site. More details about this brownfi eld site can be found on page 22 of this report.<br />
Additionally, a recent brownfi eld purchase in Basingstoke, England will house <strong>Crown</strong>’s<br />
retail branch and corporate headquarters. This 37,000-square-foot brownfi eld site allows<br />
us to consolidate three facilities into one to better serve our customers and save energy.<br />
In 2011, <strong>Crown</strong> outgrew its current facility located in Ft. Loramie, Ohio and purchased a<br />
75,000-square-foot brownfi eld facility in Minster, Ohio. This brownfi eld site will house<br />
our wire harness assembly process while providing productive use to an otherwise empty<br />
structure. The Ft. Loramie building will be repurposed.<br />
Today, by combining the recent brownfi eld sites above with over 2.8 million square feet<br />
of repurposed sites in the past, <strong>Crown</strong>'s legacy of using brownfi eld sites adds up to over<br />
5 million square feet.<br />
<strong>Crown</strong> Manufacturing Facility<br />
New Castle, Indiana<br />
6
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
• sustainable land use<br />
• environmental policy<br />
statement<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
environmental policy statement<br />
<strong>Crown</strong> is committed to leading the industry as the manufacturer of choice by providing<br />
our customers with preferred products, parts and services that will support their success<br />
as well as our own. As a part of this commitment, <strong>Crown</strong> conducts its business activities<br />
through an environmentally ethical and honest relationship with employees, customers,<br />
suppliers, contractors and communities. We strive to be industry leaders in preserving<br />
the environment for future generations. As such, we are committed to the following:<br />
• <strong>Crown</strong> provides an environmentally friendly and safe work environment for all<br />
employees, suppliers, contractors and our communities.<br />
• <strong>Crown</strong> is committed to continually evaluating, reducing and eliminating the<br />
environmental impact of its business activities, products and services.<br />
• <strong>Crown</strong> complies with all applicable local, state and federal regulations and rules.<br />
• <strong>Crown</strong> seeks opportunities to recycle waste and strives to purchase and use<br />
environmentally sustainable products.<br />
• <strong>Crown</strong> practices and promotes pollution prevention through maintenance,<br />
education and operational upgrades.<br />
• <strong>Crown</strong>’s environmental policy is communicated to employees, customers and<br />
contractors, and is available to the public.<br />
• <strong>Crown</strong> will regularly review this policy to ensure its validity and compliance<br />
throughout its facilities.<br />
<strong>Crown</strong>’s ESR 5000 Series Reach Truck<br />
7
table of contents<br />
corporate profile<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
• sustainable product<br />
development<br />
• sustainable integrated<br />
manufacturing<br />
• our commitment<br />
to customers<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
C<br />
strategic approach to sustainability<br />
rown views sustainability as a long-term strategic approach—including social, environmental<br />
and economic opportunities to achieve business objectives and contribute to a more<br />
sustainable world. As a team, we believe in minimizing the environmental impact of our<br />
product—beginning at the material level, to the product and technology level, through<br />
manufacturing. Ultimately, we are committed to providing customers with energy-efficient<br />
products to meet their application needs.<br />
As an industry leader in the material handling business, we hope to challenge the expectations<br />
of those who work in the industry by influencing processes to manufacture sustainable<br />
products. We also partner and work with customers to help them become sustainable.<br />
sustainable product development<br />
<strong>Crown</strong> designs lift trucks and technologies to maximize their lifespan, conserve resources<br />
and help customers achieve business results. At the outset, <strong>Crown</strong> lift trucks are born of<br />
more than 60 percent recycled steel. When our trucks are eventually retired, they’re up to<br />
99 percent recyclable. Overall, <strong>Crown</strong> trucks are designed to reduce human effort, energy<br />
consumption and waste.<br />
sustainable integrated manufacturing<br />
Central to the company’s sustainable manufacturing efforts is Integrated Manufacturing,<br />
through which <strong>Crown</strong> manufactures up to 85 percent of the components used in our forklifts.<br />
This exceptional level of control over our manufacturing shrinks the environmental footprint<br />
of our products, while ensuring truck dependability and reliability. This enables <strong>Crown</strong> to take<br />
a number of steps to keep sustainability top of mind while reducing waste streams.<br />
our commitment to customers<br />
<strong>Crown</strong>’s principles of sustainability extend to customer relationships and we continually<br />
seek ways to help make their operations sustainable as well. Customers understand that<br />
making decisions—such as choosing forklifts that have a long life and are more efficient—<br />
as well as technologies that focus on efficiencies, can make a big difference in their overall<br />
environmental impact.<br />
<strong>Crown</strong> believes in minimizing<br />
the environmental impact<br />
of our products—beginning<br />
at the material level, to the<br />
product and technology<br />
level, through manufacturing.<br />
We are committed to providing<br />
customers with energy-efficient<br />
products to help meet their<br />
application needs while<br />
sustaining our environment<br />
through practices that minimize<br />
waste, manage energy and<br />
maximize lifespan.<br />
8<br />
c u s t o m e r s c u s t o m e r s<br />
product development manufacturing
table of contents<br />
corporate profile<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
• life cycle assessment<br />
• product focus<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
C<br />
sustainable product development<br />
ustomers are interested in new and innovative ways to minimize waste, manage energy<br />
and maximize lifespan. These three guiding principles are embedded in our product<br />
design so that we can deliver the sustainability and efficiency that customers demand.<br />
<strong>Crown</strong> starts by designing its trucks with long lasting, durable and recyclable materials.<br />
Our trucks incorporate steel into our doors and covers to protect internal truck components<br />
and help customers save materials and money by reducing the need for replacement<br />
parts. With products and technology systems designed for long life by leveraging the<br />
inherent benefits of steel, <strong>Crown</strong> customers can rest assured our forklifts are built to<br />
be both durable and environmentally sound.<br />
<strong>Crown</strong>’s design and engineering teams conduct human-factors research by stepping out<br />
of the office to test drive our trucks, research trends and talk to expert users to discover<br />
innovative ideas that benefit our customers. With this design approach, we work to reduce<br />
our environmental impact across the entire life cycle of our products. We believe that our<br />
commitment to innovation and technology is key to achieving this reduction.<br />
With <strong>Crown</strong>’s unique business approach based on Integrated Manufacturing, <strong>Crown</strong> is<br />
able to manufacture trucks and technologies that meet our high standards for safety and<br />
quality. For instance, <strong>Crown</strong> designs and engineers its own electronics and motors for our<br />
reach trucks. This allows us to optimize performance and energy efficiency by designing<br />
the motor specifically for the application and for use with our brakes, our mast and<br />
ultimately, our internal components.<br />
manufact<br />
uring<br />
“<strong>Crown</strong> knows that the more integrated sustainable thinking is done early on in the<br />
product development process, the greater the impact it will be.”<br />
c u s t o m e r s<br />
<strong>Crown</strong> <strong>Equipment</strong> <strong>Corporation</strong> - New Bremen, OH<br />
Ray Denison, Manager of Design Services<br />
product development<br />
c u s t o m e r s<br />
9
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
• life cycle assessment<br />
• product focus<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
Design Awards and Recognition<br />
<strong>Crown</strong>’s commitment to sustainable design has been recognized with more than 50 design<br />
awards and many notable recognitions. <strong>Crown</strong> is a frequent winner in the Industrial<br />
Designers Society of America (IDSA) annual International Design Excellence Award<br />
(IDEA). A major category that determines if a product receives the award is its responsibility<br />
to society and the environment. <strong>Crown</strong> has won more IDEAs in the Commercial and<br />
Industrial <strong>Equipment</strong> category in the last 11 years than any other company. This is the<br />
sixth consecutive and 19 th overall IDEA award for <strong>Crown</strong>. Most recently, <strong>Crown</strong> was<br />
honored with a 2011 Gold IDEA award for the <strong>Crown</strong> WT 3000 Series of pallet trucks.<br />
In addition, Fast Company magazine recently recognized <strong>Crown</strong> in its feature article,<br />
United States of Design: 30 Companies That Get It. This article focused on companies that<br />
innovate, are sustainable and focus on safety while building customer loyalty and creating<br />
value. According to the publication, these companies listen to customers, understand their<br />
issues and provide products that meet their needs.<br />
life cycle assessment<br />
<strong>Crown</strong> began further evaluating the sustainability of raw materials and manufacturing<br />
processes through life cycle analysis in 2010. As <strong>Crown</strong> works toward an increasingly<br />
transparent product life cycle, we are utilizing the most effective tools and methods to<br />
best understand and develop product from the raw materials to the final disposal in mind.<br />
Life cycle assessment (LCA) provides <strong>Crown</strong> with a method to evaluate the ecological and<br />
human-health impact of our product over its entire life cycle. The LCA tools provide impact<br />
data on the environmental consequences of available materials, designs, manufacturing<br />
processes, product use patterns and throughout end-of-life disposition.<br />
Understanding environmental impacts throughout the stages of our products' life cycle<br />
allows us to implement strategies around reducing, reusing and recycling. Utilizing our<br />
life cycle analyst and LCA tools, we are able to define which design concepts produce the<br />
least environmental impact through quantifiable data. The environmental performance<br />
data added to the current design criteria (durability, reliability, aesthetics, quality, costs<br />
and others) allows us to make more informed sustainable choices.<br />
10
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
• life cycle assessment<br />
• product focus<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
product focus<br />
<strong>Crown</strong>'s determination to minimize waste, manage energy and maximize lifespan wherever<br />
possible can be seen in its product design and the manufacturing processes applied to its<br />
broad range of trucks and technologies.<br />
Longer Life, Less Replacement Parts<br />
The RM 6000 Series reach truck and TSP 6500/7000 Series turret truck feature the<br />
MonoLift mast that has proven durability and long-life characteristics.<br />
The C-5 Series cuts natural resource consumption due to its rugged, durable components<br />
and frame that offer a longer product life. Our C-5 Series includes the <strong>Crown</strong> Powerbrake<br />
that features a unique full-circle design with fewer parts and larger friction areas for<br />
improved responsiveness. The 90 percent more friction area contributes to longer brake<br />
pad life. In addition, an oil capacity of eight quarts and an internal oil cooler provides<br />
superior heat dissipation for extended oil and component life.<br />
InfoLink asset management data can help customers proactively and quickly identify<br />
maintenance issues to properly maintain equipment for optimal use and a longer life.<br />
Our innovative e-GEN braking system is standard on many electric trucks and uses<br />
AC motor torque instead of wearable brakes to stop a lift truck's motion—eliminating<br />
the need to replace or adjust wearable parts.<br />
“<strong>Crown</strong>’s collaborative teams work smart to deliver<br />
innovation above and beyond customers’ expectations<br />
by designing and manufacturing efficient products<br />
that are environmentally sound.”<br />
<strong>Crown</strong> <strong>Equipment</strong> <strong>Corporation</strong> - New Bremen, OH<br />
Mike Gallagher, Vice President - Design<br />
11
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
• life cycle assessment<br />
• product focus<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
Energy Efficiency<br />
<strong>Crown</strong> designed the RM 6000 Series reach truck and the TSP 6500/7000 Series turret truck<br />
to efficiently use energy. Standard regenerative lowering, on both the RM 6000 and the<br />
TSP 6500/7000, reduces energy consumption by returning energy to the battery during<br />
the lowering function. This feature supports fewer battery changes, more productivity,<br />
increases operating time and provides 12 to 15 percent more run time for improved energy<br />
utilization and reduced costs.<br />
In addition, the RM 6000 Series reach truck and the TSP 6500/7000 Series turret truck<br />
both reduce the energy required to run warehouses with lift heights up to 505" and 675"<br />
respectively. Instead of building additional square footage, both trucks allow facilities to<br />
store more product in a smaller footprint. All in all, the smaller the footprint, the less<br />
energy used to cool the facility, especially in freezer environments.<br />
The RM 6000 increases efficiency and saves energy through its dedicated accessory pump<br />
and motor system. This allows accessories to run more efficiently with a pump and motor<br />
more appropriately matched to the power requirements of reach, tilt and side shift. A pressuresensing<br />
device shuts the reach and retract functions off when end of stroke is reached,<br />
preventing the system from going into hydraulic relief, ultimately saving energy.<br />
Our continued release of new products and obsolescence of old allows <strong>Crown</strong> to continually<br />
improve efficiencies. Newer designs for manufacturability allow improved process efficiencies<br />
and reduced material consumption. <strong>Crown</strong>’s release<br />
of the new TSP Series truck results in a more energy<br />
efficient model with significantly fewer mechanical and<br />
electrical parts.<br />
As part of the Insite Productivity Suite, <strong>Crown</strong> InfoLink<br />
can help pinpoint areas for energy improvement. The<br />
energy dashboard reports whether the truck’s battery is<br />
changed too frequently/too soon or if the battery was not<br />
charged to the correct level. Charging a forklift’s battery<br />
prematurely can be detrimental to the battery in the<br />
long run. Additionally, InfoLink can help customers<br />
optimize fleet size and eliminate unnecessary equipment<br />
—allowing them to streamline their operations.<br />
<strong>Crown</strong>’s RM 6000 Series Reach Truck<br />
12
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
• life cycle assessment<br />
• product focus<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
The V-Force High-Frequency Modular (V-HFM) battery charger provides<br />
15 percent more efficiency than traditional chargers while fully charging electric<br />
forklift batteries to 100 percent in eight hours or less.<br />
While other charging systems achieve 70 to 80 percent<br />
efficiency, the V-HFM charger achieves 93 percent<br />
efficiency over the entire charge cycle.<br />
“As managers face increasing pressure for their fleets to be more efficient,<br />
productive and sustainable, the V-Force V-HFM Charger can help them achieve<br />
improvements in all three areas. Our high-frequency charger basically does a better<br />
job of converting energy so essentially our customers will be using less electricity<br />
to do the same amount of work.”<br />
<strong>Crown</strong> <strong>Equipment</strong> <strong>Corporation</strong> - New Bremen, OH<br />
Craig Bruns, Director of Aftermarket Support<br />
Through our ongoing commitment to hydrogen fuel cell technology, <strong>Crown</strong><br />
has qualified more than 20 of its electric forklift models to operate with<br />
various fuel cells, offering an unprecedented 29 qualified combinations<br />
of fuel cell packs and lift trucks.<br />
The C-5 Series, FC Series, RM 6000 Series and TSP 6500/7000 Series<br />
utilize energy-efficient LED lights as standard equipment. Energy-<br />
efficient AC technology is used in our full line of electric trucks, which<br />
results in much lower emissions and a reduced total cost of ownership.<br />
Add the RM 6000 and the RR 5700’s on-demand steering feature to<br />
experience additional energy savings. With on-demand steering,<br />
the steer motor does not constantly run—the motor only starts when the<br />
steer tiller is engaged, therefore saving energy when not in use.<br />
13
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
• life cycle assessment<br />
• product focus<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
Fuel Efficiency<br />
When compared to competitor IC trucks, the C-5 Series consumes 10 percent less fuel.<br />
Overall, the C-5 Series exceeds current EPA emission requirements and available fuel usage<br />
is maximized with <strong>Crown</strong>’s patent-pending eSmart Accurate Fuel Tracking feature.<br />
The C-5 also offers an Economy mode that provides industry-leading fuel economy.<br />
The C-5 Series produces 50 percent less oil waste through extended service intervals.<br />
Less Waste, Less Space<br />
<strong>Crown</strong>’s Access 1 2 3 Comprehensive System Control communicates with every truck<br />
system to safely maximize throughput. This can-based network—combined with<br />
AC technology—reduces non-solid-state components, such as relays and electrical<br />
contactors thereby saving energy.<br />
Another example of sustainable design is component commonality. This includes an<br />
integrated side shift in the RM 6000 Series reach truck. This integrated side shift<br />
uses one less weldment than the RR 5700 reach assembly. Additionally, <strong>Crown</strong>’s<br />
product design team designed some major reach components as castings rather<br />
than as fabricated weldments—reducing the amount of material used to produce<br />
these compounds.<br />
The TSP 6500/7000 Series is designed with commonality to the TSP 6000 model when<br />
possible to optimize the reuse of parts and tooling, such as the operator compartment<br />
area, drive units, tires, power unit, etc… All in all, new truck models include common<br />
components with other <strong>Crown</strong> trucks in order to optimize reuse of parts and tooling.<br />
14
table of contents<br />
corporate profile<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
• mast component cell<br />
• employee commitment<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
I<br />
sustainable integrated manufacturing<br />
ntegrated Manufacturing provides a level of control that enables unsurpassed quality and<br />
increased dependability and reliability to our customers. <strong>Crown</strong> trucks are designed and<br />
made by <strong>Crown</strong>. We manufacture drive units, motors, valve bodies, masts, power units,<br />
cylinders, electronics, wire harnesses, plastics, forks, covers/doors and more. The benefits<br />
include versatility of design, parts availability and positive customer outcomes.<br />
Our highly skilled teams employ advanced manufacturing processes and technologies, as<br />
well as sustainable environmental practices that reduce waste, control costs and increase<br />
efficiency. <strong>Crown</strong>’s commitment to sustainable manufacturing is longstanding and<br />
includes ISO 14001 certification of our environmental management systems and zero<br />
landfill at two manufacturing facilities. We believe that sustainable manufacturing<br />
is a smart business practice that we will continue to draw upon in our future<br />
ecologic enterprises.<br />
Long-term performance and value are as central to <strong>Crown</strong>’s sustainability approach as<br />
they are to our business model. By engineering and manufacturing lift trucks with longevity<br />
in mind, <strong>Crown</strong> ensures that our equipment remains up and running—and does so for<br />
a long time.<br />
“<strong>Crown</strong> offered to help us find a better way to move our material and be<br />
more efficient with our trucks. The company is a key name in lean manufacturing<br />
and they are always improving upon their own manufacturing<br />
process—so we jumped at the chance to gain their insight.”<br />
Peerless Pump - Indianapolis, IN<br />
Scott Patterson, General Manager of Horizontal Pump Business<br />
<strong>Crown</strong>’s TSP 7000 Series Turret Truck<br />
c u s t o m e r s<br />
manufact<br />
uring<br />
product development<br />
c u s t o m e r s<br />
15
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
• mast component cell<br />
• employee commitment<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
mast component cell, celina, ohio<br />
<strong>Crown</strong> is committed to improving our manufacturing process every day. For example, in<br />
our 850,000-square-foot Celina, Ohio plant, <strong>Crown</strong>’s manufacturing engineers and lean group<br />
members developed a component cell that eliminated the need to transport component<br />
parts between manufacturing sites—saving over 20,000 transportation miles and 27 tons<br />
of greenhouse gasses annually. The project required an in-depth analysis of component<br />
part processes and operations between the New Bremen, Ohio and Celina facilities.<br />
Once the travel patterns were documented and analyzed, a new strategy was developed<br />
that consolidated the manufacturing of these parts at one facility. In order to consolidate,<br />
<strong>Crown</strong> relied on the manufacturing knowledge and expertise that is embedded in our<br />
Integrated Manufacturing strategy. The team developed a patented approach to parts<br />
delivery using the TSP 6000 lift truck, a series of conveyor delivery systems, and a<br />
computerized documentation system which demonstrates both innovation and<br />
sustainability in a new manufacturing process.<br />
This project increases manufacturing efficiency, decreases transport miles and<br />
reduces cost and is only one example of <strong>Crown</strong>’s commitment to streamlining<br />
operations to save resources. Many of <strong>Crown</strong>’s projects begin with<br />
sustainability as the driving force. Any opportunity to eliminate<br />
waste and become more efficient is a win for both the<br />
environment and <strong>Crown</strong>.<br />
16
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
• mast component cell<br />
• employee commitment<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
employee commitment to sustainability<br />
<strong>Crown</strong>’s longstanding commitment to managing our environmental impact and continuous<br />
improvement is supported by a dedicated environmental team and employees around the<br />
globe. Our employees are dedicated to environmental stewardship and apply the principles<br />
of sustainability to their daily work. For instance, employees at the <strong>Crown</strong> Mexico facility<br />
developed a procedure to reuse protective caps that travel between Mexico and <strong>Crown</strong><br />
New Bremen—instead of throwing them away, the caps are reused, which saves material<br />
and reduces waste.<br />
Employees at <strong>Crown</strong>’s electronic manufacturing facility in New Bremen, Ohio have not<br />
only achieved zero landfill status and received ISO 14001 registration, but they continue to<br />
find new ways to be sustainable every day. This team of employees’ continuous improvement<br />
ideas to recycle and reuse material amounted to a significant reduction in waste and<br />
savings. The employees take great pride in reusing, recycling and not sending material to<br />
a landfill. Overall, these activities demonstrate <strong>Crown</strong>’s reliance on our priority to reduce,<br />
reuse and recycle.<br />
<strong>Crown</strong>’s SX 3000 Series<br />
Walkie-Straddle Stacker Truck<br />
17
table of contents<br />
corporate profile<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
• innovative technology<br />
• encore renewed lift trucks<br />
• fuel cells<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
T<br />
our commitment to customers<br />
he biggest impact regarding energy consumption is during our lift truck’s operation.<br />
Therefore, it is important to provide our customers with products and technologies<br />
that will enable them to use fewer resources. The following are just a few examples that<br />
illustrate <strong>Crown</strong>'s commitment to helping our customers become more sustainable.<br />
innovative technology<br />
<strong>Crown</strong> moves beyond the truck to help customers collect, measure, benchmark, analyze<br />
and act on data about their trucks. The <strong>Crown</strong> Insite Productivity Suite is our continuing<br />
commitment to help customers make more informed business decisions, lower costs and<br />
improve efficiency—now and into the future.<br />
<strong>Crown</strong> InfoLink is a wireless fleet and operator management system within the <strong>Crown</strong><br />
Insite Productivity Suite. With InfoLink, warehouse managers can receive the following<br />
actionable data: equipment status (e.g., logged on, logged off or in service), hours by operator<br />
based on status (e.g., idle, hydraulic and travel), battery or fuel status, fuel consumption<br />
and impact events.<br />
“We were anxious to see the sort of insight we would gain about our fleet utilization<br />
with <strong>Crown</strong>’s InfoLink… It wasn’t long before we were able to uncover opportunities<br />
to increase efficiencies. Only one month after installation, we determined that two<br />
stockpickers were not being utilized and that they could be removed immediately<br />
from our fleet without any change in operation.”<br />
Owens & Minor - Richmond, VA<br />
Charlie Winnagle, Director of Corporate Operations<br />
crown.com<br />
18<br />
c u s t o m e r s c u s t o m e r s<br />
product development manufacturing
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
• innovative technology<br />
• encore renewed lift trucks<br />
• fuel cells<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
Encore Renewed Lift Trucks<br />
<strong>Crown</strong> has a strong history of reclaiming and remanufacturing trucks and components to<br />
minimize environmental waste and maximize productive life spans. When <strong>Crown</strong> began<br />
remanufacturing forklifts, it did so based on the principle that its Encore line of renewed<br />
lift trucks should be the best in the industry. These remanufactured trucks enable<br />
customers to enjoy the lowest cost of ownership over the life of their vehicles and gives<br />
the original truck a “renewed” life.<br />
Another conservation-minded product line, our one-of-a-kind renewed drive units, lift<br />
truck motors and electronic modules, give customers access to nearly-new components<br />
that have been remanufactured to <strong>Crown</strong>'s exacting standards saving valuable resources.<br />
The Encore remanufacturing process begins with <strong>Crown</strong> technicians stripping each<br />
forklift down to its frame and meticulously inspecting, repairing and/or replacing every<br />
part that goes back into the forklift. Remanufacturing includes electrical, structural, drive<br />
units, hydraulics, brakes and exterior components. Any unusable components are recycled.<br />
Thanks to <strong>Crown</strong>’s integrated manufacturing process, the company has immediate access to<br />
the needed parts to quickly and effi ciently remanufacture a forklift.<br />
Encore Success in Latin America<br />
As an example of our customers understanding the sustainable nature of our Encore<br />
line of renewed lift trucks, Momatt in Latin America appreciates partnering with other<br />
sustainable companies to conserve, recycle and reuse when possible.<br />
“Momatt is working with companies that are environmentally conscious.<br />
By purchasing <strong>Crown</strong>’s Encore line of renewed lift trucks, we work toward<br />
minimizing our environmental impact.”<br />
Momatt SA de CV, Mexico<br />
Lic. Alberto Francisco Campos Montes<br />
National Sales/Marketing Manager<br />
“The <strong>Crown</strong> Encore program has been a strategic fit for our material<br />
handling needs in Anixter’s medium to small facilities where new<br />
equipment can be cost prohibitive. Our Encore trucks are completely<br />
remanufactured, look new and provide the same dependable service<br />
we have come to expect from new <strong>Crown</strong> units.”<br />
Anixter International<br />
Bob Beck, Vice President of U.S. Operations<br />
1. Durable Design<br />
Right from the start, <strong>Crown</strong> trucks<br />
are designed to last and be recycled.<br />
2. Quality Manufacturing<br />
We’re not just an “assembler.”<br />
Our Integrated Manufacturing<br />
processes result in truck systems<br />
that work—better than others.<br />
FIRST<br />
LIFE<br />
3. Truck Reclamation<br />
Unlike others, <strong>Crown</strong> has a process<br />
to accept, evaluate and recycle<br />
99 percent of truck components, up to<br />
and including complete remanufacture.<br />
4. Reliable<br />
Remanufacturing<br />
Like our initial manufacturing, we<br />
take a thorough approach by using<br />
<strong>Crown</strong> Integrity Parts and Renewed<br />
motors and drives to ensure<br />
complete system performance.<br />
2<br />
1<br />
3<br />
4<br />
5<br />
SECOND<br />
LIFE<br />
7<br />
6<br />
5. Factory Warranty<br />
& Support<br />
<strong>Crown</strong> offers a 90-day/one-year<br />
warranty with each Encore truck,<br />
as well as service and maintenance<br />
programs to support uptime for<br />
your business.<br />
6. Flexible Financing<br />
<strong>Crown</strong> offers fi nancing for Encore<br />
trucks—including leasing or full<br />
ownership options.<br />
7. Truck Recycling<br />
Encore customers can trust <strong>Crown</strong><br />
to be environmentally responsible in<br />
the recycling of end-of-life trucks.<br />
19
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
• innovative technology<br />
• encore renewed lift trucks<br />
• fuel cells<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
fuel cells<br />
The integration of hydrogen fuel cells into lift trucks embodies the he spirit of <strong>Crown</strong>'s environmentally<br />
responsible philosophy. It has the potential to reduce electricity ctricity cost in areas with high<br />
electric energy rates and reduce carbon emissions, while also improving mproving operator effi ciency.<br />
The only byproducts or emissions produced from hydrogen fuel l cells are water and heat.<br />
<strong>Crown</strong> ecologic Research and Consultation<br />
Located in Huber Heights, Ohio, <strong>Crown</strong>'s project center shares s fuel cell application-related<br />
information with customers interested in enhancing their own n sustainability eff orts by<br />
employing fuel cell-powered forklifts in their application.<br />
<strong>Crown</strong> has been researching fuel cell forklift applications for more than six years and<br />
announced its fi rst signifi cant fuel cell installation more than three years ago. In 2011,<br />
we built our 500th more than six years and<br />
three years ago. In 2011,<br />
new forklift to be operated with fuel cells. The achievement represents<br />
a notable milestone, signifying the increased adoption of this technology in the material<br />
handling industry.<br />
In 2011, <strong>Crown</strong>’s RM 6000 Series reach truck was qualifi ed as part of <strong>Crown</strong>’s fuel cell<br />
qualifi cation program for its line of electric forklifts. The fuel cell-powered ell-powered <strong>Crown</strong> RM 6000<br />
will feature fuel cell controls and gauges integrated into the truck uck dashboard and off er programmable<br />
performance settings and advanced diagnostics for or the fuel cell power unit.<br />
Recently, in Halle Belgium, <strong>Crown</strong> customer, Colruyt Group, installed a fuel cell in our<br />
SC 5300 Series counterbalance forklift. The hydrogen for the hydrogen production and<br />
fi lling station is generated with electricity from Colruyt's own on-site wind turbine and<br />
solar panels.<br />
Some current <strong>Crown</strong> forklifts that are powered by fuel cells include de the PC 4500 Series center<br />
control pallet forklift, the SP 3500 Series stockpicker and the FC 4500 Series counterbalanced<br />
forklift. Applications have varied from Walmart Canada’s sustainable tainable distribution center<br />
in Alberta to the Coca-Cola Bottling Co. Consolidated production n center in North Carolina.<br />
<strong>Crown</strong> continues to work closely with fuel cell manufacturers, , our supply chain and<br />
customers to evaluate and qualify fuel cells.<br />
“As one of the fi first rst Coca-Cola bottlers to make the move to use fuel cell lift trucks, it was important<br />
that we set the standard by partnering with a provider that has conducted signifi cant research on the<br />
technology and d had a strong commitment to its customers’ sustainability initiatives, as well as its own.<br />
After visiting <strong>Crown</strong>’s rown’s fuel fuelcellresearchcenterandtouringitsmanufacturingareas cell research center and touring its manufacturing areas, we wewereconfident<br />
were confi dent<br />
<strong>Crown</strong> was the right choice.”<br />
Coca-Cola Bottling Co. Consolidated - Charlotte, NC<br />
Dave Brown, Vice President of Manufacturing<br />
20
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
I<br />
2011 accomplishments<br />
n 2011, <strong>Crown</strong> continued its efforts to reduce its environmental impact by achieving<br />
zero landfill status at two additional facilities. <strong>Crown</strong> also invested in a community by<br />
repurposing another brownfield site in New Castle, Indiana. <strong>Crown</strong> continues to improve<br />
and build its sustainability efforts on a day-to-day basis to reinforce our commitment<br />
to minimize waste, manage energy and maximize lifespan whenever possible. “Achieving zero landfill has been such a rewarding experience and<br />
it’s carrying over into my home life as well. It has definitely raised<br />
awareness for me and my family.”<br />
two <strong>Crown</strong> facilities achieve zero landfill<br />
<strong>Crown</strong> <strong>Equipment</strong> <strong>Corporation</strong> - New Bremen, OH<br />
<strong>Crown</strong> continues to make strides in achieving zero landfill throughout its business<br />
Greg Barhorst, <strong>Crown</strong> Rental/Used Manager<br />
network. In early 2011, <strong>Crown</strong>’s electronic manufacturing plant in New Bremen, Ohio<br />
achieved zero landfill thanks to a continuous improvement team of employees who<br />
consistently collaborate on how to be more sustainable.<br />
Additionally, the Dayton, Ohio <strong>Crown</strong> Lift Truck branch achieved zero landfill status by<br />
reusing or recycling most of its waste. Branch employees approached the corporate office<br />
with a plan to achieve zero landfill, and by analyzing its waste streams and implementing<br />
reuse and recycling strategies, <strong>Crown</strong> Dayton reached its goal. Examples of this accomplishment<br />
include substituting paper towels in the restrooms with launderable cloth<br />
towels, eliminating disposable shop towels in favor of recyclable towels and increasing<br />
recycling activity. These activities resulted in an increase of 43 percent in material being<br />
recycled and an overall reduction in waste of 20 percent from a year ago.<br />
<strong>Crown</strong>’s New Knoxville, Ohio manufacturing facility was the first to achieve zero landfill<br />
in 2009. This facility continues to sustain zero landfill status in its 40,000-square-foot<br />
facility, which manufactures electric motors and plastic parts. This facility recycles 96<br />
percent of its waste with the remaining 4 percent (less than 1 ton per month) being<br />
converted into energy at a state-of-the art, waste-to-energy facility.<br />
21
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
new castle, indiana brownfield site<br />
<strong>Crown</strong> purchased an abandoned 937,000-square-foot former manufacturing plant in New Castle, Indiana to house its<br />
deep draw press operation. Refurbishment activities started with cleaning and removing oily residue off the walls and<br />
ceilings while recycling these fluids and other structural components. In fact, <strong>Crown</strong> took the old broken concrete that<br />
required replacement and ground it up for reuse at the site as backfill for other concrete work. To date, over 10,000 tons of<br />
concrete has been ground up and made ready for reuse. Additionally, we have reused Styrofoam panels as insulation at the<br />
facility and offices. Refer to Table 1.1 for more detailed information on this project. All in all, <strong>Crown</strong> has breathed new life<br />
into the facility and the local community. <strong>Crown</strong> believes that by conserving and renewing resources whenever possible,<br />
new life can not only be brought to the manufacturing facility, but also to the residents of this Midwestern city.<br />
Table 1.1 - New Castle Brownfield Accomplishments to Date<br />
Crushed and<br />
reclaimed concrete<br />
Abandoned pipe and<br />
equipment removal<br />
Factory window<br />
insulation<br />
• 6,000 tons of concrete machine bases and foundations have been removed and processed<br />
on-site to date.<br />
• The crushed material was reused to fi ll-in vacant machine pits, used as compacted fi ll at new<br />
machine foundations and added to driveways where needed.<br />
• An estimated 4,000 tons of used concrete is staged for future reuse.<br />
• Obsolete and abandoned furnaces, pipe, conduit and structures have produced more than 300 tons<br />
of scrap steel and were recycled through a local neighboring scrap yard.<br />
• Oversized air compressors and air storage tanks have been sold for reuse elsewhere.<br />
• Obsolete electrical buss rail and disconnects have been sold for reuse elsewhere.<br />
• In-plant offi ce panels comprised of three-inch-thick, aluminum-clad Styrofoam were reclaimed during<br />
plant offi ce demolition and fi tted into 2,560 sq. ft. of circa-1973 steel frame windows to reduce heating<br />
load in another area of the facility.<br />
• Factory siding panels comprised of 2½" thick steel clad Styrofoam panels were reclaimed from the<br />
boiler/compressor building demolition and fi tted into 1,920 sq. ft. of circa 1973 steel frame windows<br />
to reduce heating load in the South portion of the West Plant.<br />
• The remaining reclaimed siding panels will be reused to cover and insulate the exposed building walls<br />
after the next demolition project is completed.<br />
Factory heating • Heating units in the factory have been adjusted from drawing and heating 100 percent outside air to<br />
a mixture of outside and recirculated plant air. This results in less operating time while still providing<br />
adequate heat and proper air quality.<br />
• A temporary wall was constructed to separate occupied space in the West section of the plant from<br />
300,000 sq. ft. of vacant space to allow for lower heating levels in the vacant space.<br />
Lighting<br />
improvement<br />
• Factory light fi xtures and bulbs are being cleaned of oil fi lm to allow for proper lighting levels without<br />
installing additional fi xtures.<br />
22
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
<strong>Crown</strong>’s commitment to sustainability produced significant results in 2011. Through sustainable product design and<br />
manufacturing initiatives, environmental partnership and programs, intensive recycling efforts and alternative energy<br />
research, <strong>Crown</strong>’s focus on environmental sustainability extended to every division of our business. The following data<br />
reflects our accomplishments for 2011 and underscores our commitment to minimizing waste, managing energy and<br />
maximizing lifespan.<br />
environmental programs and partnerships<br />
<strong>Crown</strong> Omni<br />
Recycling Week<br />
Association for<br />
Manufacturing Excellence<br />
(AME) national convention<br />
Environmental and<br />
Ecologic Group Formed<br />
<strong>Crown</strong> partnered with Omni Recycling and offered employees an incentive to bring in their<br />
recycling material during a week in April. Over 15,000 pounds of scrap was recycled.<br />
<strong>Crown</strong> was invited to present its sustainability message at the AME national convention in Dallas<br />
in October 2011.<br />
<strong>Crown</strong> Mexico employees launched an environmental group that partners with the government to<br />
improve the environment through local conferences. Conferences that took place at the facilities<br />
last year include: electrical energy savings, carbon reduction and water pollution.<br />
Chlorine-Free Paper <strong>Crown</strong> Germany uses only chlorine-free paper and sustainably forested paper that is<br />
FSC certifi ed.<br />
VCA Attest <strong>Crown</strong> UK received new VCA attest for its branch. This certifi cate recognizes our compliance with<br />
health and safety regulations.<br />
alternative energy development<br />
Fuel Cell Technology<br />
Development<br />
<strong>Crown</strong> built its 500 th new forklift to be operated with fuel cells.<br />
crown.com<br />
23
table of contents<br />
corporate profile<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
sustainable manufacturing accomplishments<br />
New Castle, Indiana<br />
Brownfield<br />
New Knoxville, Ohio<br />
Zero Landfill<br />
<strong>Crown</strong> purchased a vacant 937,000-square-foot former manufacturing plant in New Castle, Indiana to<br />
house its deep draw press operation. To date, over 10,000 tons of concrete has been ground up and<br />
made ready for reuse. Additionally, reused Styrofoam panels have been repurposed as insulation at the<br />
facility and offices.<br />
<strong>Crown</strong>’s electronic manufacturing plant in New Bremen, Ohio achieved zero landfill thanks to a continuous<br />
improvement team of employees who consistently collaborate on how to be more sustainable.<br />
Mast Component Cell <strong>Crown</strong>’s manufacturing engineers and lean group members developed a component cell that<br />
eliminated the need to transport component parts between manufacturing sites—saving over<br />
20,000 transportation miles and 27 tons of greenhouse gasses annually.<br />
Wet Paint System <strong>Crown</strong> Germany installed a new wet paint cabin to conserve heat and energy. The new cabin is closed<br />
with controlled heat and air flow. The flash-off area is enclosed, which allows the parts to dry in a<br />
heated environment without heating the entire assembly bay. The air from the paint cabin and the<br />
drying area is circulated through a heat exchanger for reuse within the paint system. Additionally, the<br />
water curtain was removed, which saves water.<br />
Reduce Paper and<br />
Internal Packaging<br />
Recycle of<br />
Technological Waste<br />
and Batteries<br />
<strong>Crown</strong> Germany designed a new production order traveler packet to help improve booking accuracy<br />
and reduce paper usage. To date, paper usage has been reduced by 30 percent.<br />
<strong>Crown</strong> U.S. and <strong>Crown</strong> Mexico both recycle cell phones, bar code scanners and batteries of all sizes<br />
used in digital equipment.<br />
Reuse of Caps <strong>Crown</strong> Mexico reuses protective caps that travel between Mexico and <strong>Crown</strong> New Bremen instead of<br />
throwing them away, which saves material and reduces waste.<br />
Reuse of Rags <strong>Crown</strong> uses rags for cleaning/absorbing oil. The rags are collected, cleaned and reused. This eliminates<br />
oil-containing rags from the mixed waste and reduces the volume of oil-containing waste.<br />
Incorporation of <strong>Global</strong><br />
Recycling Symbols on<br />
Lift Truck Parts<br />
<strong>Crown</strong> will utilize the international standard (ISO 11469), in addition to the SPI code, for identification<br />
and marking of our plastic parts to provide more information on material content for end of life.<br />
VCA Certified <strong>Crown</strong> Netherlands is VCA certified, which is a quality system that secures safety and the environment.<br />
24
table of contents<br />
corporate profile<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
sustainable accomplishments<br />
Dayton, Ohio<br />
Branch Zero Landfill<br />
This <strong>Crown</strong> branch achieved zero landfill status by reusing or recycling most of its waste. The branch’s<br />
efforts resulted in an increase of 43 percent in material being recycled and an overall reduction in waste<br />
of 20 percent from a year ago.<br />
Recycled Plastic <strong>Crown</strong> Germany reorganized its parts center and recycled approximately 30 cubic meters of plastic.<br />
<strong>Global</strong> Positioning<br />
Systems (GPS) on<br />
Service Vans<br />
energy/carbon reduction<br />
Efficient Heating<br />
System<br />
Heat Retention/Double<br />
Air Lock Projects<br />
Variable Off-Peak<br />
Electric Boiler<br />
emission reduction<br />
Updated Shot Blast<br />
<strong>Equipment</strong><br />
Machining Air Quality<br />
Improvement<br />
Use of Railroad<br />
Services<br />
<strong>Crown</strong> Australia installed GPS to reduce travel time and fuel consumption while also encouraging safe<br />
driving practices.<br />
<strong>Crown</strong> Germany installed an intelligent heating system that monitors external warehouse doors and<br />
latent heat within heaters. This intelligent heating system utilizes the gathered information to reduce<br />
unnecessary heating by switching off the blower heater when warehouse roller doors are opened.<br />
<strong>Crown</strong> Germany added a new high-speed, double airlock gateway to help reduce the amount of lost<br />
heat when moving material in and out of the facility. An additional high-speed door was added to<br />
reduce heat loss and air flow between two factory bays. An additional air curtain reduces the draft<br />
created when the gate is in operation.<br />
<strong>Crown</strong> China installed a variable off-peak electric boiler that controls operation and usage during<br />
off-peak hours.<br />
<strong>Crown</strong> Germany updated its shot blasting equipment. This new flow-through shot blast has a double<br />
waterfall extraction system. In addition, air quality was increased as the area is cleaner, which results in<br />
a reduction of weld smoke.<br />
<strong>Crown</strong> Germany installed mist-/dust-/fume-extraction systems on all new and existing equipment.<br />
This system reduces the amount of water and coolant steam exhausted into the air from the<br />
machining centers.<br />
<strong>Crown</strong> Mexico now uses railroad services to transport material from Laredo to Querétaro.<br />
This is an emission reduction of 2 tons of carbon per trip, totaling over 200 tons of carbon<br />
emissions per year.<br />
25
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
reclaimed or recycled<br />
SOLID WASTE 2011 TOTALS SCRAP METAL 2011 TOTALS<br />
U.S. Units Metric U.S. Units Metric<br />
Styrofoam 3.5 Tons 3.2 Tonne Iron 28,521 Tons 25,874 Tonne<br />
Cardboard 1,041 Tons 944 Tonne Copper 42 Tons 38 Tonne<br />
Paper/Magazines 764 Tons 693 Tonne Aluminum 107 Tons 97 Tonne<br />
Manufacturing Plastics 160 Tons 145 Tonne Lead 3.5 Tons 3.2 Tonne<br />
Recycled/Reused Wood<br />
Waste<br />
287 Tons 260 Tonne MACHINERY<br />
Shot Blast Dust 510 Tons 463 Tonne Machine Coolants 328,000 G 1,241,615 L<br />
Recycled Foam 1.5 Tons 1.4 Tonne Oil and Oily Wastewaters 224,000 G 847,932 L<br />
Recycled Powder Coat<br />
Waste<br />
7.5 Tons 6.8 Tonne<br />
Air Leak Maintenance<br />
Program<br />
110 CFM 3.11 CMM<br />
Gloves and Rags Recycled 52 Tons 47.2 Tonne Machines Recycled 26 Machines 26 Machines<br />
Empty Drums 6.5 Tons 5.9 Tonne OTHER ITEMS<br />
LIFT TRUCKS Lamps and Bulbs 4,350 Bulbs 4,350 Bulbs<br />
Renewed Motors and Drives 21,085 Units 21,085 Units Small Batteries 1.8 Tons 1.6 Tonne<br />
Lift Trucks Recycled 2,170 Tons 1,969 Tonne Computers 9.3 Tons 8.4 Tonne<br />
Circuit Boards 28 Tons 25 Tonne<br />
Lift Truck Batteries 1,421 Tons 1,289 Tonne<br />
26
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
C<br />
safety and health<br />
rown invests in its employees to manufacture quality, reliable and sustainable lift trucks<br />
and technologies. Our employees know that small actions add up to a big difference. As<br />
a strong, growing worldwide company, <strong>Crown</strong> attracts individuals who are committed to<br />
teamwork, diversity, innovation and passionate problem solving and who are healthy,<br />
motivated and committed. As part of our sustainability efforts, <strong>Crown</strong> works hard to<br />
create a healthy workplace by reducing injuries and accidents and by making healthy<br />
nutrition choices available.<br />
<strong>Crown</strong> <strong>Equipment</strong> Facilities Earn Recognition from National Safety Council<br />
In 2011, <strong>Crown</strong>’s New Bremen, Ohio manufacturing headquarters received national<br />
recognition for its safety program in the area of lift truck safety. The National Safety<br />
Council awarded all eight <strong>Crown</strong> facilities with Lift Truck Operator Awards. This<br />
award recognizes forklift operators for excellence in operating lift truck fleets without<br />
recordable or lost-time injuries.<br />
This is not the first time <strong>Crown</strong> and its facilities have been recognized by the National<br />
Safety Council. In 2010, the company received an Occupational Excellence Achievement<br />
Award for its implementation of effective safety programs and initiatives. In that same year,<br />
the company’s manufacturing facility in Greencastle, Indiana, was recognized for achieving<br />
1 million consecutive man hours (10 years) without a lost time injury.<br />
<strong>Crown</strong> recently entered into a partnership with the Occupational Safety and Health<br />
Administration (OSHA) and the Industrial Truck Association (ITA). For this partnership,<br />
<strong>Crown</strong> provides input of an experienced lift truck operator to help evaluate lift truck<br />
safety issues in warehouse applications, provide input into solving these issues and review<br />
communication and training materials. This alliance between <strong>Crown</strong>, OSHA and ITA<br />
is another example of our commitment to sustainable operations through safe lift<br />
truck operations.<br />
“At <strong>Crown</strong> <strong>Equipment</strong>, we take great pride in safety excellence both in our manufacturing<br />
facilities and processes, as well as working with our customers on best practices for forklift<br />
safety. Major contributors to the continued success of our corporate safety initiatives<br />
include internal usage of our <strong>Crown</strong> training programs, including DP LeadSafe for<br />
supervisors and DP TrainSafe for trainers; as well as <strong>Crown</strong>’s InfoLink system and the<br />
company’s SafeSteps program.”<br />
<strong>Crown</strong> <strong>Equipment</strong> <strong>Corporation</strong>, New Bremen, OH<br />
Brian Duffy, Director of Corporate Environment and Manufacturing Safety<br />
27
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
programs<br />
SafeSteps Built on a foundation of positive employee reinforcement, <strong>Crown</strong>’s SafeSteps program provides an<br />
employee-managed approach to safety that is unique for a manufacturing environment. Employees<br />
recognize and evaluate fellow employees on the safety techniques they’re performing correctly rather<br />
than solely focusing on unsafe behavior. This fosters a positive learning environment that allows<br />
<strong>Crown</strong> to keep employee health and safety as a top priority, as well as ensure productivity and<br />
effi ciency in our facilities.<br />
Safety Week <strong>Crown</strong> Australia’s risk department has launched <strong>Crown</strong> Safety Week to remind employees of<br />
the value of safety and the importance of working toward ZERO HARM.<br />
Safety Workshop Series <strong>Crown</strong> Australia conducted a series of training workshops on hazard identifi cation, risk<br />
management, incident reporting and investigation.<br />
HealthWise <strong>Crown</strong>’s HealthWise program focuses on sustaining healthy employees through distribution of<br />
self-care manuals, a quarterly newsletter, diabetes care programs and insurance benefi ts. In addition,<br />
the program offers health challenges, fi tness center discounts and preventative health screenings to<br />
all employees.<br />
Healthy Living Program <strong>Crown</strong> Mexico employees are able to participate in a health program that promotes good eating<br />
habits, weight control, as well as nutritional evaluation and education. In addition, employees are<br />
offered a personal diet program along with an employee cafeteria menu designed for healthy living.<br />
Fit for Work Program <strong>Crown</strong> Australia introduced a national Fit for Work program that includes policies and procedures<br />
to become and stay healthy.<br />
National OHS<br />
Management System<br />
recognition<br />
National Safety Council<br />
Awards<br />
Association for<br />
Manufacturing<br />
Excellence (AME)<br />
national convention<br />
<strong>Crown</strong> Australia has developed an Occupational Health Management System that meets AS4801.<br />
<strong>Crown</strong>’s manufacturing headquarters received national recognition for its safety program in the area<br />
of lift truck safety. The National Safety Council awarded all eight <strong>Crown</strong> facilities with Lift Truck<br />
Operator Awards.<br />
<strong>Crown</strong> was invited to present at the AME national convention in Dallas in October 2011. Brian Duffy,<br />
<strong>Crown</strong>’s Director of Corporate Environmental and Manufacturing Safety, and Janice Clune, Safety<br />
Technician for <strong>Crown</strong>’s SafeSteps program, presented “Achieving Cultural Change Through<br />
Employee-Based Behavior Safety” to over 200 attendees. Since its inception in 2005, <strong>Crown</strong>’s<br />
SafeSteps program has created a culture of continuous improvement that has resulted in a<br />
signifi cant reduction in both recordable and lost-time injury rates.<br />
Safety Industry Award <strong>Crown</strong> Mexico received the Safe Industry Award by the government. The facility meets Mexican<br />
safety standards and requirements.<br />
Take Charge. Live Well!<br />
28
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
C<br />
awards and recognition<br />
rown <strong>Equipment</strong> has earned numerous environmental awards throughout its history. The recognitions listed below<br />
highlight the company’s sustainable manufacturing and environmental advocacy efforts. Awards and recognitions for<br />
2011 can be found in the 2011 Accomplishments section on page 21 of this report.<br />
crown's historical environmental recognition<br />
2008, 2010 State of Ohio, Governor’s Award for Outstanding Achievement in Environmental Stewardship<br />
2005 Recognized by National Partnership for Environmental Priorities<br />
2003 Designated a Waste Minimization Partner by U.S. EPA<br />
1994 Authored Paper for Society of Manufacturing Engineers on Elimination of 1,1,1-Trichloroethane<br />
1993 State of Ohio, Governor’s Pollution Prevention Award<br />
1992 Regional Finalist - U.S. EPA Administrator’s Award<br />
1991-1995 Commitment U.S. EPA 33/50 Program<br />
crown.com<br />
29
table of contents<br />
corporate profi le<br />
commitment to sustainability<br />
heritage of sustainability<br />
approach to sustainability<br />
product development<br />
integrated manufacturing<br />
commitment to customers<br />
2011 accomplishments<br />
safety and health<br />
awards and recognitions<br />
supplemental information<br />
crown.com<br />
supplemental information<br />
organizations/associations<br />
Member of Manufacturers<br />
Alliance for Productivity<br />
and Innovation (MAPI)<br />
As an active member of MAPI, <strong>Crown</strong> is able to come together with other manufacturers to<br />
exchange knowledge, build expertise and form policy.<br />
ITA/OSHA Alliance <strong>Crown</strong> recently entered into a partnership with the Occupational Safety and Health Administration<br />
(OSHA) and the Industrial Truck Association (ITA). For this partnership, <strong>Crown</strong> will provide input of<br />
an experienced lift truck operator to help evaluate lift truck safety issues in warehouse applications,<br />
provide input into solving these issues and review communication and training materials.<br />
Recytyre, Valorlub<br />
and Bebat<br />
published articles<br />
Material Handling and<br />
Logistics publication<br />
contact information<br />
As an active member of the following organizations—Recytyre, Valorlub and Bebat—<strong>Crown</strong> Belgium<br />
helps identify waste streams, formulate recycling targets; propose regulations for waste transport;<br />
selection and handling; and reorganize and promote environmentally friendly solutions.<br />
<strong>Crown</strong> published an article titled How Sustainability Leads to Profi table Business Practices. This<br />
article discusses how to become a valued corporate citizen by embarking on a path toward a more<br />
sustainable business where customers, communities, the environment and the business all benefi t.<br />
Your feedback is important to us. Please send your comments to the appropriate person below for your region.<br />
<strong>Global</strong> Contact Brian Duffy, Director of Corporate Environmental and Manufacturing Safety<br />
brian.duffy@crown.com<br />
North America Contact Tonja Rammel, Environmental Administrator<br />
tonja.rammel@crown.com<br />
Europe Contact Martin Hainge, Director of Marketing Communications EMEA<br />
martin.hainge@crown.com<br />
Asia Pacifi c Contact<br />
China<br />
Asia Pacifi c Contact<br />
Australia<br />
Jon Martin, General Manager<br />
jon.martin@crown.com<br />
Paul Jackson, Managing Director<br />
paul.jackson@crown.com<br />
30