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Xerox Employees Use Green Tactics to Boost Savings, Earn Earth Awards

Monday 15. November 2010 - Just how small is small? It's the question Xerox Corporation (NYSE:XRX) employees asked themselves when they set out to develop the smallest package possible for ColorQube solid ink. The result: a smaller package made primarily of recycled material, and one of many green, employee-driven innovations that saved the company $10.2 million, and eliminated 2.6 million pounds of waste this year.

“For 17 years our Earth Awards program has showcased how employees improve the business – and benefit the world – by eliminating waste,” said Patty Calkins, Xerox vice president, Environment, Health, Safety and Sustainability. “Xerox employees have a strong sense of pride attached to our legacy of being environmentally conscious.”
This year more than 30 nominations came from Xerox facilities around the world – including Ireland, Canada, France, the United Kingdom and the United States.
Judges considered innovation, direct benefits to Xerox, duration of the project and the documented, measurable results of each entry. Thirteen winners were chosen including:
Wilsonville, Ore.: A research team developed the smallest package possible for ColorQube solid ink. In addition to its small size, the packaging is made from 100 percent post-consumer recycled material for the tray and lid (provided by a local vendor), and a 43 percent recycled shipping box used for protection.
Another team in Wilsonville adopted Xerox’s Energy Challenge 2012 program to reduce greenhouse gas emissions. Energy savings exceeded expectations with a total of 855,000 kWh saved in facility and operations equipment. Employees altered their workspace habits by limiting the energy used by office equipment and powering off lights with energy savings totaling 852,000 kWh. Cost savings for the projects were more than $140,000.
Webster, N.Y.: A team in Webster’s EA Toner plant developed a more efficient process to handle wastewater. The changes resulted in a 60 percent reduction in wastewater sent offsite for disposal; a 50 percent reduction in the building’s waste generation; a 33 percent reduction in water required for mixing raw toner materials, and a 73 percent reduction in the amount of preparation time. Total cost savings was about $80,000 per year.
Another team from Webster achieved a goal that at one time was viewed as unachievable – zero waste to landfill. The team redesigned the EA Toner plant sludge waste handling system to be used to convert waste to energy. As a result they eliminated 50,000 pounds of waste that previously went to landfills, and saved $2,000 in operating cost. The system also helped improve safety conditions and boosted overall productivity.
Grovepoint, Ohio: Using Lean Six Sigma tools, the team assessed and significantly reduced the amount of packaging material sent to the landfill each day. They installed equipment to compact Styrofoam and cardboard, eliminating 1.5 trailers of waste per day; developed a return process for wooden pallets, saving more than $738,000 per year; and created a reuse process for the overpack boxes, which saved $3,000 per month.
Ontario, Canada: Using environmental sustainability messages to educate employees and drive revenue and sales, this team collaborated with the sales staff in a Sustainability Customer Presentation Certification program. The training reached 92 percent of the direct sales force and 70 percent of the agent representatives. The project now is being rolled out in Xerox North America.
Dundalk, Ireland: Employees developed a process to reconstruct the DocuTech DPI kits, which control the rate the ink is released on paper, rather than purchase new ones. The project eliminated 32,000 kg of material previously sent to landfills, and saved more than $132,000.