Delphi Wins Five SAE Environmental Excellence in Transportation Awards

TROY, Mich., May 14, 2003 -- Delphi Corp. was awarded five Environmental Excellence in Transportation (E2T) Awards by the Society of Automotive Engineers (SAE). The awards were won for the categories of stationary energy and emissions, mobile energy, new methods and tools, materials development and usage, and emissions and process innovations.

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"Understanding the environmental impact of our products and processes early in the development and design phases is very important at Delphi," said Dr. Andrew Brown, Jr., executive director of engineering competency, Delphi Technologies Inc./Research Labs and Product Government Affairs and Partnerships, Delphi Corp. "Delphi strives to develop environmentally friendly products and processes that support our customers' environmental initiatives and help provide improved performance."

Glenn Howarth, director of environmental services, Delphi Corp., said "Delphi believes that environmental stewardship is extremely important, and our employees demonstrate this through innovative processes, products and technologies. This SAE recognition is further proof of Delphi's commitment to help protect human health, natural resources and the global environment."

A brief description of each E2T Award winner follows:

Mobile Energy and Emissions: Delphi's Tech-2 fuel rail reduces unwanted fuel pressure oscillations that occur in return-less fuel systems. It helps decrease engine-out and evaporative emissions and eliminates hexavalent chrome by using stainless steel instead of plated steel in its design.

Delphi's Tech-2 fuel rail helps solve the problems arising from removing the pressure regulator from the fuel rail. Without the regulator, large pressure pulsations can cause fuel-control problems, resulting in higher engine-out emissions, and fuel-system noise (line hammering). Delphi's Tech-2 development offers excellent damping with fewer components and is more reliable. Also, by eliminating the chrome plating process, the design saves 8 million gallons of water, 640,000 kwh of electricity, 2,400 MCF of natural gas, 6,000 lbs of hexavalent chrome and 4,000 lbs. of zinc.

Stationary Energy and Emissions: Delphi employees used energy-flow mapping to decrease wastewater at two manufacturing facilities resulting in reduced environmental impact, cost savings, and future cost avoidance.

Water consumption levels at the two Delphi facilities exceeded the capacity of the local water well resulting in government water restrictions. These restrictions would require the facilities to truck water in while waiting for permits and drilling a new well at a total cost of more than $200,000. Delphi's Energy Management Team used energy-flow mapping to produce a comprehensive understanding of the facilities' water use and then developed a coordinated plan to reduce use cost-effectively. The team found they could reroute some of the water systems, reuse some of the process water for other applications, and reduce the required water flow to the water treatment facility. With these initiatives, water usage went from a projected 66,000 cubic meters to less than 44,000 (a reduction of 5,300,000 gallons). Benefits included the elimination of the new well, trucked-in water, and wastewater discharge to the local river.

New Methods and Tools: Delphi's use of math-based metal-removal simulation was responsible for waste-savings involving scrap and tooling, a decrease in consumed energy by reducing part production cycle time and machine tool horsepower, and a decline in coolant consumption.

Math-based metal-removal simulation tools represent the latest advances in machining process modeling. It provides a systematic, scientific approach to analyze the machining processes compared to traditional cut and trial methods. Simulation tools allow utilization of virtual component machining and predictive engineering parameters such as cycle time, cutting forces, tool life, and part quality to optimize machining operations. Benefits gained from simulation tools include: scrap reduction through improved process capability and balanced cutting forces; machine tool optimization by predicting process requirements before capital purchase; energy consumption reduction by decreasing part-production cycle time and cutting forces; and trimming coolant consumption by eliminating machines and reducing part cycle times while improving process efficiency.

Materials Development and Usage: Delphi is now using 100-percent recycled Santoprene plastic instead of virgin material for several automotive components to reduce waste, environmental impact and energy usage.

Previously, byproduct Santoprene created in the various molding processes was either landfilled or used in applications that had less stringent material requirements. Through the establishment of an infrastructure to supply quality recycled material to Delphi and other molders, the use of the byproduct material stream was significantly enhanced. By using recycled Santoprene on two parts, over 28 million lbs. of raw material and waste were reduced per year. Energy conservation is also enhanced through these process changes. Other parts are currently undergoing conversion so that they can utilize the recycled material.

Process Innovations: Delphi demonstrated industry leadership by switching from a solvent-based to a water-based adhesive to bond brake material to shoes. This project, involving significant collaboration between Delphi engineers and material suppliers, saved equipment and chemical costs while significantly reducing volatile organic compounds (VOC) emissions. The new adhesive also proved to be more robust.

With two new product lines for brake parts, Delphi used its chemical materials assessment process to evaluate different manufacturing processes and their impact on costs, equipment and the environment. A traditional method of using solvent-based adhesive was found to be expensive and to have an environmental impact. After material evaluations, Delphi selected a water- based adhesive that reduced VOC emissions by 98 percent. In addition, the new application was more robust and less complex, saving capital costs.

Delphi is a Gold sponsor in the Mobile Energy and Emissions category and a Silver sponsor in the New Methods and Tools category.

For more information about Delphi, visit Delphi's media room at www.delphi.com/media .

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