Topic : Think Blue. Factory At VWSA - IWMSA
Topic:Think Blue. Factory at VWSAPresenter:Date:Nick Chapman – Plant Engineer17 October 2013
Ecological sustainability is among our most important challenges“By 2018 we want to be at thetop of the automotive industry– financially andenvironmentally.”Prof. Dr. Martin Winterkorn,Chairman of VolkswagenAktiengesellschaftWith the Think Blue. Factory. we acceptecological responsibility and make an important contributiontowards ecological leadership.
The Road to Think(ing) BlueMotion TechnologiesThink Blue.Think Blue. Factory.Volkswagen’s gen’s attitudetowardsenvironmentalsustainability.One product. Onelabel.Many products &technologies.A strategic umbrellabrand.TDITSIDSG Our answer to the CO2debate and the Toyotahybrid approach Expansion of enviro.friendly products andtechnologies BlueMotion became themost successfulenvironmentally friendlycar label Clear communication ofadvantages to thecustomer and focus onone brand20052008 Expansion of BlueMotionTechnologies Communication beyondproducts andtechnologies Provides customer anoverall impression ofVW’s enviro. activities2010We use “ThinkBlue. Factory.” tocarry the conceptover to production.2011
What is Think Blue. Factory?Reduce the environmental burden of all VWplants around the world.Measure our progress by the defined keyfigures for: Energy consumption Water consumption Waste produced CO2 emissions Solvent emissionsTarget:25%-25%by 2018
VW Group Strategy
Four Focus AreasSocietyMake Ecologicalproduction transparentGreen BuildingCertificationSponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO MileEfficiencyCombine environmentalprotection & economicsby utilizing resourcesefficiently in the factoryTB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste StreamManagementNew Press ShopEnergysupplyConstantly increasingthe proportion ofsustainable andresource-conservingenergySolar Thermal for HotWater GenerationRenewable Energy :Amatola Green PowerSynchronaEmployeesThink and act according toecological rulesInternal communicationsLearning Academy modulesShow of Hands Volunteers“Quarterly” CampaignsIdeas ManagementcompetitionsEmployee Offerings
Society – Sponsorship ExampleName: South African Marine Rehabilitation andEducation Centre (SAMREC)Sponsorship duration: 2012 - 2013Reasoning: SAMREC is a non-profit organisation, formed in2000 to care for sick/injured African Penguins. St Croix Island in Nelson Mandela Bay is thebiggest African Penguin breeding colony in theworld. Alignment with Dyer Island Trust.Nature of sponsorship: VWSA supports the SAMREC Sea School programme financially. VW Show of Hands Volunteers renovated the Penguin general ward created an interactive trail and open-air classroom for learners.
SocietyMake Ecologicalproduction transparentGreen BuildingCertificationSponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO MileEfficiencyCombine environmentalprotection & economicsby utilizing resourcesefficiently in the factoryTB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste StreamManagementNew Press ShopEnergysupplyConstantly increasingthe proportion ofsustainable andresource-conservingenergySolar Thermal for HotWater GenerationRenewable Energy :Amatola Green PowerSynchronaEmployeesThink and act according toecological rulesInternal communicationsLearning Academy modulesShow of Hands Volunteers“Quarterly” CampaignsIdeas ManagementcompetitionsEmployee Offerings
We are transforming our plants into ecological role modelsNew factories:constructed asecological factoriesEcological factoryExistingproductionknowledgeExisting factories:migration paths towardsbecoming ecologicalfactoriesIndividualmigration paths forexisting factories
Think Blue. Factory. Is for Everyone!
Think Blue. Factory Workshops - MeasuresBody Shop 1-MetalFinish Line ConceptBase Load Reduction(Combined all Business)Low Flow Shower HeadsOptimise lighting system– Turn lights off that arenot neededWater Harvesting – NewPress ShopShop Specific ElectricityMonitoringTimer on HydraulicPower PacksReduce water usage –water testTurn off the 6xmembrane filters inAssembly when systemis not in use.Switch off compressedair over non-productionperiodsCooling TowermodificationsLow Flow Shower HeadsFES (filtration unit)partial switch offBody Shop Base LoadReductionPolystyrene RecyclingUse more efficient LaserTechnologySwitch off CoolingTowers to Reduce BaseLoadVSD for CompressorCooling Tower Fan –Body ShopDe-Link Press Shop from10bar compressed airCapacity Upgrade of NewPaint Shop – Shut downrest of Paint Shop 1Reduction in Electro coatWasteBase Coat Filter ChangePaint Recovery – PaintKitchenReduce number ofstirrers in Effluent PlantRaw TankSwitch Lights Off in PaintShop 1Base Load ReductionPaint ShopOptimize Oven BakingCyclesRun around coil system– recover heat fromexhaustRedirect exhaust air(Wheel) IntermediateOven2012New Robot GenerationImprove sorting ofvarious waste streamsSwarf blow off nozzlesIncreased Cardboard &Plastic RecyclingFacilitiesDirect Process MaterialUsageEnergy Saving ClampsLatest Press ShopTechnologyLight ManagementSystem for all AreasReplace 400W HPS with200W CFLEliminate and Replace400W High Bay with160WLight Switches in RobotCells and Automatedswitch offInstall Compressed AirMetering – Phase 1Condition Based CoolingTower Bleed OffImprovements to effluentplant processesRoof for ChillersReduction of Paint MixWasteMaximize Start-up /shutdown sequence2013Solar Thermal Energy forE-Coat of HOP at PEPlant1-line concept – run Vivoproduction on 3rd shiftConsolidate rear axlemanufacturing –Relocate from E/plantInterior Paint RobotInstallationEnd of production localEA111 A05Compressed AirMetering – Phase 2(Assy, Paint, Body Shop)Bell, Bell Application (2 xEsta Stations)Solar-Thermal energy forPaint Shop (hot watergenerationInstall Run Around CoilSystem to Recover Heatfrom Oven ExhaustsMaterial reduction - A05replace A04 as VIVORainwater HarvestingVSD for CompressorCooling TowerReplace PlantCompressor 4 with VSDCompressorReplace PlantCompressor 4 with VSDCompressorAlternative (nickel-free)cold Pre-TreatmentNew generation ofthermal oxidizer (TNV)2017201620152014Paint ShopAssembly HallInfrastructurePE PlantBody ShopPress ShopCommon to All AreasEngine Plant
Liquid Effluent (Gulping)Effluent Separated Solids (Sludge)2012 – Increased Liquid Effluent treatment capacity - reduced GulpingExisting SettlerNew additional Conical Settlers May 2012
Migration Projects 2012/2013Sealer Recycling andApplication (2012)Bell Bell Application(2013)Paint Mix Waste(2013)Paint ShopPaint ShopPaint Shop1. Sealer Recycling ProjectNew Efficient Paint SprayingTechnologyFacility change to treat andremove additional paint waste.Savings:Savings:5.3 tons/annum Waste,3.4 tons/annum VOC94 tons/annum Waste2. Application OptimisationSavings:99.4 tons/annum waste1.34 tons/annum VOC
Migration Projects 2012/2013Cooling Towers(2012)Hydraulic Powerpacks(2012)Cooling Towers(2013)Body ShopEngine PlantBody ShopCooling Towers switched offduring weekends by technicians.Timers fitted onto hydraulicpowerpacks to switch off duringweekends.Variable speed drives installed oneach of the 55kW fans.Savings:346 MWh/annum355 tons CO2/annumSavings:105 MWh/annum108 tons CO2/annumSavings:116 MWh/annum119 tons CO2/annum
Ecological Factories – New Press ShopLatest Press Shop Technology (2012)Press ShopOld Press Shop OperationIn normal Start/Stop mode the clutch andbrake operation consumes additional energyNew Press Shop OperationNew Press Line operates with ContinuousWave Motion including energy efficientmotors – no application of Clutch/ BrakeExpected 2014 full Savings:Electricity: 1282 MWh/annumCO2: 1316 tons/annum
Migration Projects 2012/2013Reusable Interlayers : Implementation has eliminated cardboard interlayers.
Think Blue. Factory. Waste Separation2010Waste Separation Project started in Production Departments with basic training.2011Waste Management Training and Awareness strategy was developed.Waste Separation Project rolled out in all production departments2012Additional compartmentalised trolleys provided and labelled per waste type.Project scope extended to office areas for implementation2013Waste Management Contract Specification created with incentive for Contractor toincrease profit by increased waste separation and recycling.
Think Blue. Factory. RecycleIdentify Opportunities to recycle wherever possible!
SocietyMake Ecologicalproduction transparentGreen BuildingCertificationSponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO MileEfficiencyCombine environmentalprotection & economicsby utilizing resourcesefficiently in the factoryTB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste StreamManagementNew Press ShopEnergysupplyConstantly increasingthe proportion ofsustainable andresource-conservingenergySolar Thermal for HotWater GenerationRenewable Energy :Amatola Green PowerSynchronaEmployeesThink and act according toecological rulesInternal communicationsLearning Academy modulesShow of Hands Volunteers“Quarterly” CampaignsIdeas ManagementcompetitionsEmployee Offerings
Solar Thermal ProjectTitle: Solar Thermal supplementing of Water HeatingSupplier:EisenmannSavings:0.017 MWh/unitProject DescriptionSolar thermal panels for Factory Roof Installation : The hot water requirements of the existing pre-treatment shall be supported by a solar systemLPG Savings PS2 :132 608 kg First Year LPG Savings PE Plant :TBCPotential Further savings :Heat pump to further utilise heat and reduce Chiller Electrical Consumption
SocietyMake Ecologicalproduction transparentGreen BuildingCertificationSponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO MileEfficiencyCombine environmentalprotection & economicsby utilizing resourcesefficiently in the factoryTB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste StreamManagementNew Press ShopEnergysupplyConstantly increasingthe proportion ofsustainable andresource-conservingenergySolar Thermal for HotWater GenerationRenewable Energy :Amatola Green PowerSynchronaEmployeesThink and act according toecological rulesInternal communicationsLearning Academy modulesShow of Hands Volunteers“Quarterly” CampaignsIdeas ManagementcompetitionsEmployee Offerings
E-Learning Modules772 People have completed the module (Sep 2013)
Internal Communication
Employee VolunteerismShow of Hands – Employee Volunteer Programme2011 Nonkqubela Primary School Orsmond TB Hospital Lake Farm Alien Vegetation Project2012 Siyaphambili Pre Primary School SOS Children's Home Limekhaya High School South African Marine Rehabilitation andEducation Centre (SAMREC)2013 Maranatha Streetworker Trust Beautification of Algoa Road
Think Blue. Factory. Measurement.Monthly Reporting to Board of Management : Focus on achieving Targets.
Think Blue. Factory – Results to Date
Think Blue. Factory – Awards2012 Top Green Organisation AwardInstitute of Waste Management of Southern Africa, in association with theEastern Cape Department of Economic Development and Environmental AffairsThe competition focused on organisations’ excellence and innovationpractices in managing and improving air quality, biodiversity, energyefficiency, water usage and waste issues.2012 Exporter Club Environmental AwardThe company’s drive to reduce its carbon footprint withimplementation of new Technologies, employee awareness,Measurement systems and programs to reduce the use resources.
We can – Can you? Think Blue.Thank You
EA111 A05 Consolidate rear axle manufacturing – Relocate from E/plant Compressed Air Metering – Phase 2 (Assy, Paint, Body Shop) 2012 Optimize Oven Baking Cycles Run around coil system – recover heat from exhaust Redirect exhaust air (Wheel) Intermediate Oven Reduce number of stirrers
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