Cummins Inc. 2007 Sustainability Report

Manufacturing Operations
For perspective on our areas of
environmental focus at the facility level,
a general description of the manufacturing
operations by business unit follows.
Cummins Engine: Within the Cummins
Engine Business, manufacturing facilities
employees conduct product design,
research and development, engine
manufacturing and engine and component
reconditioning. Engine assembly facilities
perform engine block and component
machining, assembly, painting, alkaline bath
parts washing and engine performance
testing. Product design and engine testing
are the primary operations in the research
and development technical centers where
production processes are limited.
Engine testing is conducted in stationary
test stands or cells, where product
performance information is measured
as engines run at various duty cycles.
Test cells also are used for certification
testing to ensure products meet
emissions requirements. Rebuild/
reconditioning facilities perform engine
tear-down and reassembly, using alkaline
parts washing processes.
Cummins Components:
The Components Group includes four
separate business units; Cummins Filtration,
Cummins Fuel Systems, Cummins Turbo
Technologies and Cummins Emission
Solutions. Facility operations primarily
involve filtration and exhaust product
design, research and development, filter,
and exhaust component assembly, and
product distribution and warehousing.
Key operations conducted among the
Components Group divisions include filter,
fuel systems, turbocharger and exhaust
60 Cummins Inc. 2007 Sustainability Report
component assembly, metal stamping, tube
bending and component machining, welding,
product assembly, painting and performance
testing.
Cummins Power Generation:
Cummins Power Generation Business facility
operations primarily involve product design,
research and development, alternator
manufacturing, assembly of generator sets,
switchgear and controls and product testing.
Alternator manufacturing facilities perform
component machining, lamination stamping,
rotor and stator winding, resin impregnation
and alternator assembly.
Assembly facilities perform housing
fabrication, genset assembly, switchgear
and controls assembly, painting, alkaline
bath parts washing and genset performance
testing. Product design and performance
testing are conducted in the research and
development technical centers. Genset
testing is conducted in stationary test
stands/cells, where product performance
information is measured while gensets are
run at various duty cycles. Test cells also
are used for certification testing to ensure
products meet emissions requirements.
Waste Streams
The primary waste streams generated at
Cummins manufacturing facilities include
waste paint and associated materials, paint
filters, wastewater sludge and filter cake,
machine coolant, used oil and resins. Metals
and metal parts that cannot be reconditioned
for re-use in Cummins products are salvaged
for off-site recycling, as are used oils. Other
waste streams include filter media and resins.
At most facilities, machine coolant is recycled
until ineffective and ultimately added to the
wastewater stream for pretreatment prior to
discharge to public treatment works.