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Beyçelik Gestamp/Çelikform Gestamp Product Enf-of-Life Management Plan

PRODUCT END-OF-LIFE MANAGEMENT PLAN 

1. Objective 

The purpose of this directive is to minimize the environmental impact of automotive parts designed and manufactured by Beyçelik Gestamp and Çelikform Gestamp at the end of their life cycle, to support circular economy principles, to reduce the consumption of natural resources, and to ensure the highest possible rate of product recycling. 

The directive defines a management system compliant with ISO 14001, ELV Directive (2000/53/EC), REACH, RoHS, GADSL, IMDS, TSRS, GRI, SBTi, and OEM customer requirements. 

2. Scope 

This instruction covers the lifecycle, from design to end of service life, of pressed parts, chassis components, welded subassemblies, safety parts, and sheet metal automotive components produced at Beyçelik Gestamp and Çelikform Gestamp’s operations in Turkey and Romania. 

Included Companies: 

  • Beyçelik Gestamp Automotive Industry Inc. 
  • Çelikform Gestamp Automotive Inc. 
  • Beyçelik Gestamp Romania SRL 

3. Responsibilities 

  • Environment and Sustainability: Development of end-of-life strategy, KPI tracking, circular economy projects, reporting of recycling performance, and sustainability reporting. 
  • R&D: Design for Recycling, Design for Circularity, material optimization, product disassembly and recyclability analyses. 
  • Quality: IMDS, ELV, PPAP, material verification, and OEM customer requirements. 
  • Procurement: Recycled content management, low-carbon steel sourcing, and supplier sustainability assessment. 
  • Production: Management of scrap management, waste sorting, and recycling processes. 

4. End-of-Life Management Process 

Order 

Process Step 

  

1 

Product Design 

2 

Material Selection 

3 

IMDS & ELV Compliance 

4 

Mass Production & Shipment to Customer 

5 

Driving 

6 

Vehicle Scrapping & Parts Disassembly 

7 

Metal Recycling & New Steel Production 

8 

New Product 

5. Design Principles 

Newly developed products aim for the use of recyclable materials, material optimization, a low carbon footprint, easy disassembly, uniform material use, absence of hazardous substances, and a long service life. 

6. Material Management 

The company prefers recyclable, low-carbon, high-strength steel and recyclable single-polymer plastics. 

7. Legal Compliance 

ELV, REACH, RoHS, GADSL and SVHC regulations are continuously monitored and every new product is checked before PPAP. 

8. OEM Requirements 

Customers are provided with IMDS records, ELV compliance, material composition, SVHC declaration, PCF, LCA, recyclability rate, and critical raw material information. 

 

 

9. External Stakeholder Collaboration (End-of-Life Management)

This clause describes the symbiotic relationship the company has established with other actors in the automotive value chain, extending beyond its own internal operations. 

9.1. Detail: It involves not only managing our own waste but also working in an integrated manner with the actors involved in the recycling process of the automobile when its life cycle ends (Manufacturer Responsibility Organizations, recycling facilities, universities). 

9.2. Beyçelik Gestamp Studies and Projects: 

  • University-Industry Collaboration: The “Advanced Recycling Material Analysis” project conducted with Bursa Technical University (BTU). R&D studies on the use of automotive chassis parts as industrial raw materials in a different form at the end of their service life. 
  • Sector Coalitions: Active participation in “Circular Economy and Waste Management Standards” development projects within the Sustainability Working Groups of the Automotive Suppliers Association (TAYSAD).

10. User Information and Proper Disposal

It is a guidance mechanism that enables the user (OEM or vehicle owner) to take the correct action when disposing of or recycling the part. 

10.1. Detail: This is a data and labeling system that reminds the user that the product is not “waste” but a “valuable raw material resource”. 

10.2. Beyçelik Gestamp Studies and Projects: 

  • Digital Material Passport (IMDS Integration): IMDS data entries prepared for our OEM customers include the complete chemical composition of the part and recycling restrictions. This data serves as a “manual of use” guiding authorized recycling facilities at the end of the vehicle’s life. 
  • QR Code Traceability Project: Efforts to provide access to the “Disassembly and Disposal Protocol” (Disassembly Guide) for specific components via QR codes located on the components or packaging. 
  • Recycling Manuals: “Part Removal and Recycling Guide” shared with OEM customers. This guide provides technical guidance to recycling facilities, especially in the removal of safety parts (seat rails, chassis boosters). 

11. Packaging Optimization

The primary packaging used to transport a product from the manufacturing facility to the customer line should be designed in a way that facilitates disposal processes. 

11.1. Detail: The goal is to facilitate recycling by removing complex layers of packaging (foam, nylon, mixed plastic). 

 

11.2.Beyçelik Gestamp Studies and Projects: 

  • “Monomaterial” Packaging Transition: A project to switch from previously used multi-layer protective coatings to 100% recyclable “Single Polymer” based packaging (PE only or PP only). 
  • Lightweighting Projects: Reducing the amount of plastic/cardboard used in packaging design through static calculations, without compromising transport safety. This directly reduces waste in the customer’s production line. 
  • Metal Crates and Reusable Equipment: Metal foldable crates replace single-use wooden or plastic pallets. These crates can be used 100+ times between facilities as part of a circular economy initiative. 

12. Design forDisassembly 

The goal is to ensure that the part can be quickly removed from the car at the end of its service life, without requiring any tools or extensive processing. 

12.1. Detail: Connecting the parts using mechanical (snap-fitting) methods instead of glue or permanent welding reduces disassembly time and cost. 

12.2. Beyçelik Gestamp Studies and Projects: 

  • Modular Chassis Design: Design improvements in next-generation electric vehicle (EV) projects that utilize mechanically adjustable and easily detachable components instead of welded chassis parts. 
  • Standard Fastener Usage: Design standards for using standard screw types found in every recycling facility, instead of special/specific screws. 

13. Recycling Management 

Steel, aluminum, plastic, cardboard, wood, packaging, and electronic waste generated during production are sent to licensed facilities using a “zero waste landfill” approach. 

14. Circular Economy Roadmap (2026–2040) 

Period 

Aim 

Short Term (2026-2028) 

Implementation of instructions across all facilities, ensuring 100% compliance with ELV and IMDS standards. 

Medium Term (2029-2035) 

Mandatory recyclability analyses, widespread use of LCA/PCF, and a 35% recycled steel rate. 

Long Term (2036-2040) 

Full integration of circular economy principles and a target of 40% recycled content. 

15. KPIs 

Indicator 

Aim 

Period 

ELV compliance 

100% 

Short Term (2026-2028) 

IMDS timely login 

100% 

Short Term (2026-2028) 

Scrap recycling 

≥99% 

Medium Term (2029-2035) 

Recyclable product 

≥97% 

Long Term (2036-2040) 

Reusable packaging 

≥90% 

Medium Term (2029-2035) 

Prohibited substance non-compliance 

0 

Short Term (2026-2028) 

SVHC notification 

100% 

Short Term (2026-2028) 

Medium Term (2029-2035) 

Analysis in new projects 

100% 

Short Term (2026-2028) 

Medium Term (2029-2035) 

16. Monitoring and Reporting 

The results are used in Management Review, ISO 14001, Sustainability Report, EcoVadis, CDP and TSRS reporting. 

17. Risk and Opportunity Analysis 

Risk/Opportunity 

Action 

Legislative Changes 

Continuous monitoring and updating. 

Supplier Non-Compliance 

Sustainability audits 

EcoVadis/SBTi Score 

Circular economy improvements 

18. RACI Responsibility Matrix 

Activity 

Environment/ 

Sustainability 

R&D 

Quality 

Purchasing 

EOL Policy 

A 

C 

C 

I 

Design 

C 

A 

C 

I 

IMDS Management 

C 

R 

A 

I 

Scrap Management 

C 

I 

C 

A 

A: Accountable R: Responsible C: Consulted I: Informed 

19. Performance Indicators (KPI Dashboard) 

KPI results are evaluated quarterly and presented to senior management. 

20. Roadmap Details (2026-2040) 

  • 2026: Implementation start and full compliance. 
  • 2030: Integration of LCA/PCF processes into all projects. 
  • 2040: 40% recycled content and full integration. 

21. Process Flowchart 

Customer Request → Design → Material Selection → Regulatory Check → IMDS → Production → Shipping → Scrapping → Recycling → New Product. 

22. Reference Documents 

ISO 14001:2015, ISO 14040/44, ELV Directive, REACH, RoHS, GADSL, IMDS, GRI, SBTi. 

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