OMB No. 2010-0032
Expiration Date 01/31/2010
2004 Performance Track Annual Performance Report















ASMO North Carolina, Inc
A040068
 Year 3 Annual Performance Report

























SECTION A: GENERAL FACILITY INFORMATION

A.1Name of your facility:
ASMO North Carolina, Inc

A.2Name of your parent company:
ASMO Co., Ltd.

A.3Facility contact person for the Performance Track program:
  Name:Mr. Danny Yount
  Title:Environment, Health, and Safety Specialist
  Phone:(704) 878-8571
  Fax:(704) 872-9786
  Email:dyount@asmo-na.com

A.4
Facility location:
  Street Address:470 Crawford Road
  Address Cont:
  City:Statesville
  State:NC
  Zip Code:28625


Mailing address (if different from above):
  Mailing Address:
  Address Cont:
  City:
  State:
  Zip Code:

A.5
Facility's website address (if any):
http://www.asmo-na.com

A.6
Number of employees (full-time equivalents) who currently work in the facility:
100-499

A.7
North American Industrial Classification System (NAICS) Code(s) that is(are) used to classify business at the facility:
336322        

A.8
In your application and, perhaps, in previous annual performance reports, you described what your facility does or makes. Have there been any (additional) changes to your facility's list of products and/or activities? If yes, please list them here:

Yes

2004-05: Started making our new next generation motors: K-Blower and GS (PW) Motors.

A.9
Have the environmental requirements applicable to your facility changed during this reporting period? If yes, please describe these changes here.

Yes
We do not have to submit an annual air toxic report but we will have to submit an air toxic report before we renew our air permit. We have added a Stormwater Permit to our site.


SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

B.1.aWhen was an EMS assessment last conducted by an independent party at your facility?
2004

If an assessment was conducted during 2004, please provide the type (e.g., ISO 14001 certification), the scope, and the month(s) of each assessment.

Type
Scope
Dates
ISO14001 Recertification DNV Registrar Audited ASMO N.C., Inc. on ISO14001:1996 Elements:
General Req'ts-4.1, Policy-4.2 Aspects-4.3.1 Legal-4.3.2, Obj. & Targets4.3.3, EMS Program-4.3.4, Struc.& Resp-4.4.1, Training-4.4.2, Communication-4.4.3, EMS Doc-4.4.4, Doc.Cnt-4.4.5, Oper.Cnt-4.4.6, Emer.Prep-4.4.7, Monitor & Meas-4.5.1, Nonconform-4.5.2, Records-4.5.3, EMS Audits-4.5.4, Mgt.Review-4.6. 		  February  2004  



B.1.bWhen was an internal EMS assessment last conducted at your facility?
2004

If an assessment was conducted during 2004, please provide the scope and month(s) of each assessment.

Scope
Dates

EHS Dept: Mgt.Review, Operation Control, EMS Audits.

February  2004

Armature Lines: Oper.Control, Policy, Aspects/Impacts, EMS Programs, Nonconformance, Monitor and Measurement, Emer.Prep., Communication, Training, Struc.& Resp.

March  2004

Support Groups(Facility, Maintn, WasteWater Treatment): Oper.Control, Emer.Prep., Policy, Aspects/Impacts, Obj.& Targets, EMS Programs, Struc. & Resp., Training, Communication, Monitor and Measurement.

April  2004

Assembly Lines: Policy, Aspects/Impacts, Obj & Targets, EMS Programs, Struc. & Resp, Training, Communication, Oper.Control, Emer.Prep, Monitor & Measurement.

May  2004



B.1.cWhen was an internal or corporate compliance audit last conducted at your facility?
2004

If an audit was conducted during 2004, please provide the scope and the month(s) of each audit, and indicate who conducted the audit(s) (e.g., facility staff, corporate groups, third party). (Don't include audits, inspections, or site visits by regulatory or external organizations).

Scope
Dates
Who conducted the audit

Air Emissions, Hazardous Waste, Hazardous Materials, Medical Wastes, EPCRA, TSCA, Storm Water, Solid Wastes, Waste Water, Universal Wastes, Drinking Water, SPCC, PCB's, Asbestos, CFC's, FIFRA, UST / AST

April  2004DENSO or ASMO -Environmental Specialists



B.1.d(Optional) If you would like to describe any other audits or inspections that were conducted at your facility, please do so here.

We conduct monthly safety & environmental inspections each month of all processes.

B.1.eBriefly summarize corrective actions taken and other improvements made as a result of your EMS assessments and compliance audits.

EMS Assessments - 01/CEA: Process Water Chart, EHS set an upper limit for warning facilities when to check for problem with conductivity probe. Problem could be dirty probe or probe in need of calibration. Result if no action - Excess water discharged to wastewater treatment. 02/CEA: Legal & Other Req'ts had not clearly identified these req'ts. ASMO obtained customer, other requirements, and updated legal requirements, and updated ASMO's procedure listing all of these requirements. 03/CEA: Internal Audit Summary Report- Was updated and will be kept updated. 04/CEA-Calibration procedure and records did not include process water conductivity calibration record from the contractor. This has been updated. 05/CEA: Roles and Responsiblities were updated to include who would respond to different possible spills for when different chemicals are received and unloaded.

Compliance Audit: R-1: SPCC had not been updated. ASMO contracted a professional engineer to review and update ASMO's SPCC Plan. R-2: ASMO did not have a current updated copy of the Sludge Management Plan/ Spill Control Plan. ASMO has added an updated Sludge Mgt.Plan/ Spill Control Plan. R-3: Compliance Auditors found potential Storm Water Exposure to Industrial Activity. ASMO has requested and received a new Storm Water Permit. Storm Water Sampling will occur this year and at the end of the Permit.R-4: Baghouse filter was not being maintained on one of the armature lines. The powder residue was cleaned up and the bagfilters maintenance was updated. Filter on internal exhaust was added to bagfilter. R-5: Waste Manifests had discrepancies which were done without ANC authorization or approval. Waste company procedures were modified to require ANC written authorization or approval.

B.1.fHas your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?
Yes

If no, please explain your plans to correct these instances.



B.1.gWhen was the last Senior Management review of your EMS completed?
March  2005
Who was the senior manager present at the review?
Name: Mr. David Clifton
Title: Director / Vice-President / General Manager

B.2.aISO 14001 Certification. Is your facility currently certified to ISO 14001?
Yes

B.2.bIs your facility a Responsible Care-certified facility?
No

B.3Environmental Aspects Identification. When did your facility last conduct a systematic identification and/or review of your environmental aspects?
February  2005

B.4Progress Toward Achieving Objectives and Targets. In the table below, please provide a narrative summary of progress made toward EMS objectives and targets other than those reported as Environmental Performance Commitments in Section C. You may limit the summary to environmental aspects that are significant and towards which progress has been made during the reporting year. Do you have additional environmental aspects to report? Yes



Environmental Aspect
Progress Made This Year (e.g., quantitative or qualitative improvements, activities conducted)
Water UsageContinued to make progress towards reduction of use of water. ANC ANC Goal Year Gal./Year Gal/Year 1999 14,549,573 2000 13,981,055 13,094,615 2001 11,104,054 13,094,615 2002 9,180,137 13,094,615 2003 9,035,524 13,094,615 2004 8,500,352 13,094,615


SECTION C: ENVIRONMENTAL PERFORMANCE COMMITMENTS

COMMITMENT 1

Category:Air Emissions
Aspect:Emissions of VOCs
Baseline
Year 1
Year 2
Year 3
Performance
Commitment
Calendar Year:
2001
2002
2003
2004
2004
Actual Quantity (per year):
41
31
28
27.5
28
Measurement Units:
tons
   Other:
Normalizing Factor:
1.0
1.03
1.00
1.073
1.0 *
Basis for your Normalizing Factor:
Units Painted in 2004 = 3,717,413 Units Painted in 2003 = 3,633,068 Units Painted in 2001 = 3,473,371 Calc.= 3,717,413/3,473,371 = 1.073
Normalized Quantity per year:
41
30.1
28
25.63
28
* Estimated

C.1.bBriefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
Due to formaldehyde increasing 200lbs. Note: Propane was inadvertently left out the last several years. It is too difficult to find the data to add back propane VOC's. Propane is used only in one (1) forklift. Propane VOC's for 2004 = 7697 lbs or 3.8 tons. 3.8 tons is not included in 2004. Formaldehyde increased due to change in MSDS on Rogers Molding Compound. Material is now called Vyncolit, and Vyncolit now lists < 1% Formaldehyde, where Rogers reported no Formaldehyde. VOC's included are: Formaldehyde, Methanol, Acetone, DMF, Benzene, Acetylene, Propane, Isobutane, MEK, DBP, Naphthalene, Butane, Ethylene glycol, 2-Methylpentane, Toluene, Phenol, THF, Cellosolve, 2-Butoxyethanol, 2-2-Methoxyethoxyethanol, 2-2-ethoxyethoxyethanol, butyl acetate, acetic acid, xylene, heptane, propylene. C1: VOC Base Line in Application was changed from 126 to 119.5 tons and was for Year 1999. The current level at the time of the application was 89 tons. The correct amount after end of year calculations were completed was 97.45 tons for the year 2000. This information was faxed to Kim Bosworth on 9/30/03 and to Connie Raines on 2/13/04.

C.1.cPlease list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).



COMMITMENT 2

Category:Materials Use
Aspect:Hazardous Materials Use
Baseline
Year 1
Year 2
Year 3
Performance
Commitment
Calendar Year:
2001
2002
2003
2004
2004
Actual Quantity (per year):
7.4
6.4
7.2
6.97
5.5
Measurement Units:
tons
   Other:
Normalizing Factor:
1.0
1.03
1.0
.9613
1.0 *
Basis for your Normalizing Factor:
Units Produced in 2004 = 13,912,978 Units Produced in 2003= 14,697,239 Units Produced in 2001 = 14,472,379 Calculation = 13,912,978 / 14,472,379 = .9613
Normalized Quantity per year:
7.4
6.21
7.2
7.25
5.5
* Estimated

C.2.bBriefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
Lead compounds, Toluene, Dichloroethane, Perchloroethylene, cyanide compounds, tin compounds continued to decline in usage. Formaldehyde and TEA (Triethanolamine) increased in usage. Formaldehyde increased due to RX-611 (Parent Product) Material Safety Data Sheet (MSDS) started listing chemical % in 2003, where before the company did not list any formaldehyde. New company called Vycolit, started listing Formaldehyde on new MSDS. TEA has increased because the product TEA is used in, Castrol Syntillo 9902 has increased in usage due to production requirements in the Shaft department. By elimination of Painted Housings, Balance Putty, and Lead Soldering; the Toluene, Lead, Xylene, and Tin Compounds would be reduced. Reduction of Production for Painted Housings and Armatures requiring Balance Putty will occur in 2007 due to design change of Blower Motors.

C.2.cPlease list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).



COMMITMENT 3

Category:Waste
Aspect:Total Solid Waste
Baseline
Year 1
Year 2
Year 3
Performance
Commitment
Calendar Year:
2001
2002
2003
2004
2004
Actual Quantity (per year):
611
452
364
336.9
354
Measurement Units:
tons
   Other:
Normalizing Factor:
1.0
1.03
1.0
.9613
1.0 *
Basis for your Normalizing Factor:
Units Produced in 2004 = 13,912,978 Units Produced in 2003 = 14,697,239 Units Produced in 2001 = 14,472,379 Calculation = 13,912,978 / 14,472,379 = .9613
Normalized Quantity per year:
611
438.83
364
350.46
354
* Estimated

C.3.bBriefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
2003 tons of solid and sludge waste generated = 325.3 tons 2004 tons of solid and sludge waste generated = 336.9 tons 336.9 - 325.3 tons = Increased by 11.3 tons of solid and sludge waste materials Solid waste did decrease: 2003= 165.09 and 2004 =152.18 tons or - 12.91 tons. Sludge waste increased: 2004 = 184.7 tons and 2003 = 160.2 or + 24.5 tons. Wood waste changed from 45.9 to 66.5 tons or increase of 20.6 tons. Note: 1. Solid waste decreased due to increase in recycling of paper & plastics. 2. Sludge waste increased due to more oil is being removed from wastewater, increasing oily sludge and filter cake sludge. 3. Wood waste increased due to more new equipment coming in wood crates. All wood waste is turned into compost at the Iredell Landfill.

C.3.cPlease list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).



COMMITMENT 4

Category:Waste
Aspect:Total Solid Waste
Specific Information on Aspect (Optional):Reduction in Non-returnable Packaging. Packaging Materials Used to ship incoming materials: Change from non-Returnable Packaging (Cardboard) to Returnable Packaging (Plastic Reusable Totes)
Baseline
Year 1
Year 2
Year 3
Performance
Commitment
Calendar Year:
2001
2002
2003
2004
2004
Actual Quantity (per year):
289
333
307
317
250
Measurement Units:
tons
   Other:
Normalizing Factor:
1.0
1.03
1.0
.9613
1.0 *
Basis for your Normalizing Factor:
Units Produced in 2004 = 13,912,978 Units Produced in 2003 = 14,697,239 Units Produced in 2001 = 14,472,379 Calculation = 13,912,978 / 14,472,379 = .9613
Normalized Quantity per year:
289
323.3
307
329.76
250
* Estimated

C.4.bBriefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
C4: One time use Packaging: On 2/27/02, I emailed Bill Paton and requested he change the application to the following: Current Level = 319 to 444 tons. Level trying to achieve in 3 years = 502 to 355 tons. I faxed this same information to Kim Bosworth on 9/30/03, and then again to Connie Raines on 2/13/04. Tons are tons of cardboard recycled. Note: Measure cardboard incoming that is recycled, which indicates increase usage of returnable totes, if cardboard recycling indicates a reduction. 2003 2004 Tons Tons ANC 156 115 AMT 89 74 AAC 62 128 Total Pkg 307 317 % Reduction -30.8 -28.6 Goal 354.9 354.9 New Goal 221.8 221.8 AMT and ANC continued to decrease use of one time packaging. AAC had to increase due to shipments to South American countries and due to increase in CKD Parts that come in one time use packaging.

C.4.cPlease list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).


SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING




D.1Please briefly describe the activities that your facility conducted during the year to interact with the community on environmental issues and to report publicly on environmental performance.

I , Danny Yount, attend one Iredell County Board of Commissioners Meeting and one City of Statesville's Council Meeting each year. Last year, I attended the 9/20/04 City of Statesville Council Meeting and on 9/21/04, I attended the Iredell County Board of Commissioners. At each meeting, I reviewed ASMO North Carolina's Environmental Performance of the previous year. ASMO North Carolina puts their annual Environmental Report on the company's website: www.asmo-na.com. I will be requesting information systems to put the 2004 ASMO North Carolina, Inc. Environmental Report on to the company's website by 4/11/05.

D.2Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public.

Web Site
Meetings
URL: http://www.asmo-na.com


Attachments (if applicable) :