Tremco CPG Wigan Reduces Waste and Costs through Sustainable Manufacturing
Effective waste management is no longer just an operational concern—it’s a crucial component of sustainable manufacturing that impacts both environmental and business success. Faced with escalating disposal costs and a desire to advance environmental sustainability, Tremco CPG undertook a significant waste reduction project at its manufacturing Wigan facility. Here’s an in-depth look at how Tremco CPG Wigan achieved measurable improvements.
The Challenge of Waste Reduction
Manufacturing facilities often face complex waste management challenges. For Tremco CPG Wigan, waste disposal costs had reached £431,000 per year in 2023. The facility lacked adequate waste segregation processes, classifying all waste as hazardous, which compounded costs and created inefficiencies. Beyond financial concerns, ensuring compliance with ISO14001 standards and minimizing environmental impacts were top priorities.
These issues pressured the facility to find sustainable solutions that would improve waste management, reduce costs and align with RPM’s sustainability goals.
The DMAIC Approach to Driving Change
To tackle these challenges, Tremco CPG Wigan adopted the DMAIC methodology (Define, Measure, Analyze, Improve and Control). Rooted in lean manufacturing principles, DMAIC provided a structured and data-driven way to identify and resolve the root causes of inefficiencies.
Under the leadership of Emma Grady, Project Leader and Purchasing Lead at Wigan’s facility, the team achieved significant, measurable results in a structured and controlled approach..
Key Initiatives Implemented
Here are the focal points of Tremco CPG Wigan’s sustainable manufacturing Green Belt project:
- Dedicated Waste Segregation Bins
New bins were introduced to sort hazardous, recyclable and general waste, promoting a circular economy by facilitating better recycling practices.
- Hazardous Waste Training
Associates received training to identify and handle hazardous materials safely and efficiently, reducing associated risks.
- Detailed Waste Logging Systems
A comprehensive logging process was rolled out to track waste effectively and ensure transparency in disposal.
- Partnering for Disposal Efficiency
Collaboration with strategic service providers, such as Biffa, the RPM contracted waste and recycling solutions vendor in the UK, allowed Tremco CPG Wigan to improve waste stream segregation, significantly increase recycling efforts and dramatically enhance the overall efficiencies in its disposal activities.
- Process Optimization
Optimized waste collection schedules and better resource allocation ensured a streamlined and sustainable workflow.
The Results and Savings
The efforts delivered impressive results for Tremco CPG Wigan:
- 75 metric tons of waste reduced annually.
- £130,000 in annual savings, achieved through effective cost management.
- 100% landfill diversion achieved, which is helping RPM meet its 2025 sustainability goals.
These outcomes demonstrate the potential of sustainable manufacturing practices within operations, paving the way for meaningful environmental and economic gains.
The Role of Stakeholder Engagement
This initiative highlighted the power of collaboration:
- Associate Training: Fostered a company-wide culture of sustainability and alignment with environmental sustainability initiatives.
- Cross-Functional Teams: Collaborative efforts across departments ensured a thorough and organized approach to implementing changes.
- Service Provider Partnerships: Partnerships facilitated optimized disposal processes.
The success of the Green Belt project sets a powerful example for other manufacturing facilities striving for sustainable solutions.
Driving the Future of Sustainable Manufacturing
Tremco CPG Wigan’s waste reduction Green Belt project demonstrates how manufacturing businesses can become more efficient by adopting lean manufacturing and improving waste management. By combining structured methodologies with innovative processes and strong stakeholder engagement, the facility achieved operational excellence while taking significant steps toward environmental sustainability.
