Document 36gb6D2Y7bXe01wn69Ry2LwJ

EXECUTIVE SUMMARY k ' U- `C `'-A. *.'Vy.v, f Introduction CARCINOCKNS IN TllEWORK PEACE 7Z. - \A-C- The Task Force on Carcinogens in the Workplace was established by the Engineering ond Research and Manufacturing and Suoply Subcommittees to identify carcinogens nnd quan 7^*0- tities in use, set targets for elimination ahead of regulation, take steps to find substitutes, develop a directive nnd workplnn ond orgnnize to identify substunccs systematically. The P.cia'-'a . Vl v xLv aE (llU^ Task Force assignment responded to evidence that cancer may be a serious occupational concern nnd to the Company's ond public concern with regard to protection of the environ ment and public Jiculth.< AdUitionullyrJ.be Company has been subjected to a growing number of.laws which regulute material use, transport, handling and disposal. In summary, internal i.t end external pressures retarding hazardous substance control and compliance hove increased A.VVAV^a.ulu--sub~stantially since .March, 1977, when Directive B-101 assigned responsibilities within the -i-wWi vll\n'^r( h1 e_ /.. . v<>h.Sh i Past Company Actions l ty.*- 7 .S' ( >V-/ - l>.{, fuLt/t i </V (' / /<? P t Vxub- -.xt < 1 jy -v * Since 1977, the Company has removed lead chromates'and molybdates from paint (except special order). ."Tris" flame retardant from fabrics and instituted. controls' on asbestos, including a Vehicle Engineering directive that newly designed components should not contain asbestos (documented exceptions must be encapsulated or resin coated). v. tnvi -v. /A, .. v 1"-' ,v v i-*^ ---------------- -- Spreyed-on fireproofing has been asbestos-free since 1969 for new and reworked construc tion. Several manufacturing standards prohibit asbestos as a constituent. Benzene exposure been reduced or eliminated at San Jose and Central Laboratories since 1978. Ventilation \vas increased at Romeo to minimize hazards from paint-related chromium compounds. /'"C . 7 r . ^, ( Carcinogenic Substances J .-M. J r_A-z'-rt 1* , ^ I 1/,x The Task Force has identified sixtv-seven (67) carcinogens in use in the automotive industry. "7 Twenty-six (26) of those are currently regulated byOSHA; the balance have been proposed for new regulation. More-restrtctive-standards have been proposed for some of those sub stances currently regulated. Thirty-one (31) substances are reported to the Michigan- Pcpartmcnt of Natural Resources for computation of water surveillance fees. Michigan .r ''l"r J plants used 1.3 million pounds of the twelve (12) carcinogens on the MDNR list. The largest use was 641 thousand pounds of acrylonitrile at the PPV Point Plant. Similar-data is not cur rently required to be reported in-the other states. The list-of-carcinogens was prioritized by the Task Force according to impact on the Company to identify the top eight (81. The top . pi^^three f the eight-priority substances, asbestos, chromium compounds and benzene, were f examined in detail. \ at:- Asbestos is used by the Company primarily in vehicle brakes, clutches, gaskets and for nonproduction roofing, millboard and core/mold-making materials. Medical lUr v.`- vU , Y .SKi H. ^ evidence links inhalation of asbestos dust to lung cancer, mesothelioma and other diseases. The present OSHA limit is 2 fibers per cc of air (2 million fibers per cubic meter) which is proposed to be reduced to 0.1 f/ec as early-as this year. I vr Chromium compounds are used primarily in paints and inks for production and nonproduction use. Medical evidence links hexevalent chromium compounds to lung cancer, liver and kidney damage and other diseases. The present OSHA limit is 52 \ rv mg per rn of air which is proposed to be reduced to 1 mg/nC. i Benzene occurs primarily in coke oven operations as a by-product. It is a residual constituent of solvents, primers, adhesives, lubricating oils, fuels and hvdrnulic fluids. Medical evidence links inhalation nnd contact with benzene to leukemia, blood disorders and other diseases. OSllA hss proposed a limit of 1 ppm in air time ---- . --- weight,ed average in 8 hours. 'v . v*k > / a. L (. C V - A' -u - x. c < - Li. xL,- ^ ^ 8003 1507 Vv Ft Specific lists of bulk materials nnd ports for production ond nonproduetion use hove been developed. A new computer dntn base is being developed. Materials and Toxicology System (MATS), which links health, engineering, and manufacturing dutn bases to facilitate rapid identification of carcinogen'applications 12nd quarter 1981). The engineering release system has been audited nnd is being updated to extend materials identification to oil parts. jl Product Engineering Procedure PEP 3-189 has been rewritten to require systematic review of suspect carcinogens and input to the data base. D lK_ cLfoiu. '< J.* x 7V.\ V, ,'J I f v x L c-F t ui fi-vx. ' KA vvUL At l 4 CAtc i . e) VL-i ui'Lr'-'* C'-Jr'6 PRODUCED BY FORD (Continued) . T -A' {/ u [j.' '" jvt. Strategy nnd Workplan The search for asbestos, chromium compounds nnd benzene defined the number of pnrt matcrinls containing these substances ns listed in the table below. Where possible, the applientions were divided into three groups: A - Known substitute mnterinl without mnjor redesign, B - Known substitute materia! with mnjor redesign nnd C - No known substitute or advanced engineering required. The dutu is directional only. There remain many support applications which require time-consuming analyses for identification. Bulk Mntcrinls nnd Pnrts JV t /. fw-A-*- Production A B C Total Nonproduction A B C Totnl Asbestos Chromium Compounds Benzene 34 49 22 - - 25 * 15 105 25 15 8 98 81 3 8 34 213 58 __ c : 4. Strategies hove been formulated to eliminate or control these "substances. _ T recommended strategy is to proceed now to eliminate these three carcinogens by Job JM, ----- 1985; in light of competitive and regulatory pressures, and Company experience. Where elimination eunnot be contained, institute controls on design, process unri exposure. It is judged that the elimination timetable is practical for Group A asbestos, chromium compounds and benzene-containing parts and materials. For those applications requiring major redesign (Croup B, e.g., drum broke linings) the elimination timetable would have to be adjusted to reflect Company cycle plans although .G.M. hus stated tin intent to eliminate asbestos by 1985. Finally, where no known substitute exists (Group C), advanced engineering will have to be completed before a elimination timetable can be established. A generalized workplan has been prepared on the basis of the evaluation of the carcinogens already referred to. The workplan requires central program management, with action imple mentation by NAAO/DPO Product Engineering Offices, Purchasing activities, Vehicle acti vities and the Manufacturing and Supply Staffs. It is judged that approximately a year is required to complete the sorting of the three carcinogens into the known substitute, mnjor redesign and advanced project groups. It is judged that one additional year would be required to implement the most feasible product actions not requiring major redesign. Substitution requiring redesign would take 33 months for vehicle or major powertrain pro- EramsRecommendations u ____ ...... v Ik s.it ^ ^ Achievement of the recommended strategy requires an integrated approach throughout the Company and a sustained effort over a number of years. The Task Force recommends: J. Establish a Hazardous Substance Control Committee choired by Environmental and Safety Engineering Staff. The Task Force would be discontinued. .2 Assign Carcinogen Program manager control responsibility to Environmental and Safety Engineering Stuff. v-; v ^ / j J;---- Request-Environmental and Safety Stn-IF-Sc-establish eoreinogen elimination timetables ` re ior-the-61? known carcinogens for review nnd approval by the subcommittees. (The Tusk Force has requested General Managers and Chief Engineers to recommend dircctionnl timetables.) T Direct att affected organizations to proceed with the elimination of Group A asbestos, chromium compounds nnd benzene for Job tt 1, 1985. Jt. <i Request that NAAO Product Engineering Offices and Manufacturing Staff present to the subcommittee specific action pluns nnd timing for the Group A applications Identified. J6.A Provide odvunce progrnm funding to develop designs and/or matcrinls for new parts to Identify reliability, cost and weight implications of alternative designs (Group C). J.^-Adopt-ar the Company enreinogen listing the 67 current OSHA-regiilotod nnd proposed ` Category I substances. Establish the top eight priorities proposed by the Tusk Force as^ Company priorities. 8003 1508 Engineering Staff - F.&RS Manufacturing Stuff May i, 1980 PRODUCED BY FORD