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Global ecologic™ Report - Crown Equipment Corporation

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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

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