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INTERNSCHIP REPORTBMW RECYCLING (VS-5)

Stéphane ChapuisTrainee by Material flow management (VS-53)01/03/2004-31/08/2004

RecyclingChapuis15.06.2004Slide 2

PLAN

– A SHORT BMW Group PORTRAIT

– BMW RECYCLING

– PERSONNAL CONTRIBUTION

– VISIT OF PLANTS

– PROFESSIONAL AND CULTURAL BALANCE


BMW Group – a Portrait

The Founding Fathers – Aviation Pioneers.The Munich plants run by Munich aviation pioneers Karl Rapp and Gustav Otto form the starting point for Bayerische Motorenwerke.

Karl Rapp

Gustav Otto1911to1913


BMW Group – a PortraitBMW Takes Off.Foundation of BMW GmbH as a limited company. Registration of the white-and-blue logo as the Company's official trademark. Production of the first aircraft engine – the BMW IIIa power unit.

1917



BMW on Four Wheels.Taking over Fahrzeugfabrik Eisenach, BMW enters the car business.

1928



CleanEnergy.Hydrogen is the fuel of the future. BMW has been testing hydrogen drive since 1978 and is now developing this technology for series production.

from1978



The BMW Group Re-Aligns.The BMW Group concentrates on premium segments with the BMW, MINI and Rolls-Royce brands.

Rolls-RoyceStarting in 2003, the BMW Group assumes responsibility for the Rolls-Royce brand.

BMWThe BMW brand model line-up is enlarged by the 1 Series in the premium lower midrange segment, the 6 Series in the large coupé and convertible market segments as well as theX3 im sports activity verhicle segment.

MINIMINI enters production in April 2001. Currently MINIs are sold in more than 70 countries the world over.

from2000


Development and Production Network.



BMW Group – Recycling


BMW Group- Recycling activities.Main areas of responsibility.

Political Framework /Legislation

Design for Recycling

Recycling SystemsRecycling andDismantling Centre

Material Cycle Management


BMW Group – RecyclingRecycling and dismantling centre.Fonctioning and recycling techniques:


BMW Group – RecyclingRecycling and dismantling centre, a pilot plant.

Functions : -Recycles all preseries and prototype vehicles of the BMW Group.

- Develops recycling techniques (processes and tools).

- Conducts dismantling analyses and evaluates recycling processes.

- Works as a training centre and also a public relation tool.

Employees : 14

Area : 1800 m2

Throughput / year: 1800 vehicles (2361 t)

Output/ year : 1700 t Body shells, 500 t used parts, 78 t operating fluids, 31 t batteries, 30 t plastic materials, 22 t non ferrous metal.


BMW Group – RecyclingEuropean framework for automobile recycling.

• A free take back of end-of-life vehicles in 2007.

• Employement of identification standard for parts and components.

• Recovery quotas:

Recovery > 85 %Recovery > 85 %

Waste site disposal < 15 %Waste site disposal < 15 %

Energy recovery < 5 %Energy recovery < 5 %

2006Reuse and materialrecycling > 80 %

2006Reuse and materialrecycling > 80 %

2015

> 95 %

< 5 %

< 10 %> 85 %

2015

> 95 %

< 5 %

< 10 %> 85 %



Organisation of the recycling departement.



Design for recycling.

Dismantling AnalysisIDIS-International DismantlingInformation System

Recycling targets inProduct Development Process

Requirementsand tools



Material cycle management.

- Construction of economically feasible material recycling loops(production waste, waste from repairs, scrap cars)

- Consulting R&D: Recycling considering selection of materials- Consulting production divisions: waste minimized production

technologies- Minimising waste during the car´s life cycle- Minimizing material loops affecting critical substances - Minimizing resource consumption in production, product use

and recovery of cars


BMW Group – RecyclingEstablishment of material recycling loops.


BMW Group – RecyclingExample: a plastic recycling loop.

Dismantling and sorting of parts

Recycling

Reuse


BMW Group – RecyclingExample: MINI, an optimized car for recycling.


Goal: Establishment of description cards for front and rear bumpers of BMW´s cars.

Tools: -IAP software, a database of drawings with material information.

-ETK software, a database of drawings with material information.

-SDF software, a database of parts lists of cars.

-The RDC for dismantling information.

Formation: a 3 days practical internschip at the RDC.

Personal opinion: a good job of data management which has improved myorganisation sense.

Difficulties: problem with german vocabulary for car´s parts (at thebeginning).

BMW Group – RecyclingMaterial´s Checklist of bumpers (1/2).


BMW Group – RecyclingMaterial´s Checklist of bumpers (2/2).

Process: -To check each part´s material thanks to IAP and ETK softwares.

-To check if all parts are recorded with lists of SDF software.

-To recommend a dismantling process.

Result:


BMW Group – RecyclingFinancial analysis.

Goal: Establishement of a parametric table in order to calculate theprofit/non profit which depends on a lot of parameters.

Tools: -Documents from recycling company- Excel.

Personal opinion: An unhabitual but very interresting job which gave meseveral notions to lead and discuss an economy analysis.

Difficulties: Several difficulties due to the amount of parameters but thebest means to avoid a mistake is to ask someonelse to check your results.

Process: Built the table´s frame then make of it a dynamic table byconnecting the parameters through formulaes.


BMW Group – RecyclingFinancial analysis table (1/2).


BMW Group – RecyclingFinancial analysis table (2/2).


BMW Group – RecyclingFinancial analysis.

Goal: Thanks to the previous dynamic table I have evaluated theinfluence of some main parameters on the profit. It has also been used to check what profit could be reached.

Result:


BMW Group – RecyclingRecycling rates.


BMW Group – RecyclingModelisation of a sorting process (1/4)

ASR

SieveDefoaming

(special maschine)

Air classification

Defibering

Fines PUR-Foam Fiber rich Plastics39% of ASR 3% of ASR 39% of ASR 20% of ASR

-Organic fines

-Fe/ FeO fines

-Glass/ Copper fines

-Dust

Washing

Drying

Baling


BMW Group – RecyclingFines (2/4)


BMW Group – RecyclingFiber rich (3/4)


BMW Group – RecyclingPlastics rich (4/4)


BMW Group – RecyclingA sample of the whole recycling process.

Source: “TwinRec- Bridging the Gap of Car Recycling in Europe”


BMW Group – RecyclingOther activities.

–Establishment of PowerPoint presentations

–Text translations

–Manual of the fonctionning of TAIS sofware I used during 4 months

–Updating of booklets

–Establishment and presentation of a recital about my work

–Taking photos of car parts after their dismantling


Recycling

Clean energy

BMW Group – Plants & exhibitionsVisit of the EarthLounge of Munich .

Sustainability. It can be done.

Corporate sustainability is a business approach to create long termshareholder value by embracing opportunites and managing risks derivingfrom economic, environmental and social developments.

Traffic management

Social responsablity


BMW Group – Plants & exhibitionsVisit of Wackersdorf´s plant


BMW Group – Plants & exhibitionsOther visits

•Forschungs und Innovations Zentrum (FIZ).

•BMW M GmbH.

•BMW Werk München.

•A shredding plant nearIngolstadt


BMW Group – Plants & exhibitionsOther visits

•A plastic recycling plant


Conclusion

•Technical balance

•Human balance

I can not finish without saying many thanks to MrKlemens Graser for all, either on the professional frame

or on a cultural point of view.

Thanks also for people from recycling departement especially for material flow management´s people: Dr. Franze, Hr. Hoock, Dr. Tartler


Thank you very much for your time!

INTERNSCHIP REPORT�BMW RECYCLING (VS-5)PLANBMW Group – a PortraitBMW Group – a PortraitBMW Group – a PortraitBMW Group – RecyclingBMW Group- Recycling activities.�Main areas of responsibility.BMW Group – Recycling