topic : think blue. factory at vwsa vwsa thinkblue factory... · 2020-01-27 · ecological...

Topic: Think Blue. Factory at VWSA

Presenter: Nick Chapman – Plant Engineer

Date: 17 October 2013

Ecological sustainability is among our most important challenges

With the Think Blue. Factory. we accept ecological responsibility -and make an important contribution towards ecological leadership.

“By 2018 we want to be at the top of the automotive industry – financially and environmentally.”

Prof. Dr. Martin Winterkorn,

Chairman of Volkswagen

Aktiengesellschaft

Product

BlueMotion

One product. One label.

Manufacturing

Think Blue. Factory.

Volkswagen’s attitude towards environmental sustainability.

The Road to Think(ing) Blue.

Product

BlueMotion Technologies

Many products & technologies. A strategic umbrella brand.

Customer

Think Blue.

Volkswagen’s attitude towards environmental sustainability.

• Our answer to the CO2

debate and the Toyota

hybrid approach

• BlueMotion became the

most successful

environmentally friendly

car label

2005 2011

We use “Think Blue. Factory.” to carry the concept

over to production.

• Expansion of enviro.

friendly products and

technologies

• Clear communication of

advantages to the

customer and focus on

one brand

2008

DSGTSITDI

• Expansion of BlueMotion

Technologies

• Communication beyond

products and

technologies

• Provides customer an

overall impression of

VW’s enviro. activities

2010

What is Think Blue. Factory?

Reduce the environmental burden of all VW

plants around the world.

Measure our progress by the defined key

figures for:

• Energy consumption• Energy consumption

• Water consumption

• Waste produced

• CO2 emissions

• Solvent emissions

25% Target:

-25% by 2018

VW Group Strategy

SocietyEnergy

supplyEmployeesEfficiency

Four Focus Areas

Make Ecological production transparent

Green Building Certification

Sponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO Mile




Constantly increasing the proportion of sustainable and resource-conserving energy

Solar Thermal for Hot Water Generation

Renewable Energy :Amatola Green PowerSynchrona




supply

Think and act according to ecological rules

Internal communications

Learning Academy modulesShow of Hands Volunteers“Quarterly” CampaignsIdeas Management competitionsEmployee Offerings




Combine environmental protection & economics by utilizing resources efficiently in the factory

TB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste Stream Management

New Press Shop



New Press Shop

Society – Sponsorship Example

Name: South African Marine Rehabilitation and

Education Centre (SAMREC)

Sponsorship duration: 2012 - 2013

Reasoning:

• SAMREC is a non-profit organisation, formed in

2000 to care for sick/injured African Penguins.

• St Croix Island in Nelson Mandela Bay is the • St Croix Island in Nelson Mandela Bay is the

biggest African Penguin breeding colony in the

world.

• 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.

SocietyEnergy














supply









New Press Shop



New Press Shop

We are transforming our plants into ecological role models

New factories:

constructed as

ecological factories

Ecological factory

Existing

Existing factories:

migration paths towards

becoming ecological

factories

Individual

migration paths for

existing factories

Existing

production

knowledge

Think Blue. Factory. Is for Everyone!

Improve sorting of various waste streams

1-line concept – run Vivo production on 3rd shift

Install Run Around Coil

New Robot Generation

Energy Saving Clamps

Use more efficient Laser Technology

Body Shop 1-Metal Finish Line Concept

Alternative (nickel-free) cold Pre-Treatment

New generation of thermal oxidizer (TNV)

VSD for Compressor Cooling Tower

Replace Plant Compressor 4 with VSD

Compressor

Replace Plant Compressor 4 with VSD

Compressor

Solar Thermal Energy for E-Coat of HOP at PE

Plant

Latest Press Shop Technology

Shop Specific Electricity Monitoring

Timer on Hydraulic Power Packs

Switch off compressed

Turn off the 6x membrane filters in

Assembly when system is not in use.

Optimise lighting system – Turn lights off that are

not needed

Reduce water usage –water test

Base Load Reduction (Combined all Business)

Water Harvesting – New Press Shop

Low Flow Shower Heads

Think Blue. Factory Workshops - Measures

Paint Shop

Infrastructure

Body Shop

Engine Plant

Assembly Hall

PE Plant

Press Shop

Common to All Areas

2013

Roof for Chillers

Light Management System for all Areas

Reduction of Paint Mix Waste

Maximize Start-up / shutdown sequence

Improvements to effluent plant processes

Install Compressed Air Metering – Phase 1

Light Switches in Robot Cells and Automated

switch off

Eliminate and Replace 400W High Bay with

160W

various waste streams

Replace 400W HPS with 200W CFL

Condition Based Cooling Tower Bleed Off

2015

Interior Paint Robot Installation

Solar-Thermal energy for Paint Shop (hot water

generation

Rainwater Harvesting 2016

Install Run Around Coil System to Recover Heat

from Oven Exhausts

Material reduction - A05 replace A04 as VIVO

2017

thermal oxidizer (TNV)

2014

Bell, Bell Application (2 x Esta Stations)

End of production local EA111 A05

Consolidate rear axle manufacturing –

Relocate from E/plant

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 in Effluent Plant

Raw Tank

Switch Lights Off in Paint Shop 1

Base Load Reduction Paint Shop

Capacity Upgrade of New Paint Shop – Shut down

rest of Paint Shop 1

Reduction in Electro coat Waste

Base Coat Filter Change Paint Recovery – Paint

Kitchen

Direct Process Material Usage

VSD for Compressor Cooling Tower Fan –

Body Shop

Increased Cardboard & Plastic Recycling

Facilities

Polystyrene Recycling

Cooling Tower modifications

Body Shop Base Load Reduction

Switch off compressed air over non-production

periods

Swarf blow off nozzlesFES (filtration unit) partial switch off

Switch off Cooling Towers to Reduce Base

Load

De-Link Press Shop from 10bar compressed air

Low Flow Shower Heads

2012 – Increased Liquid Effluent treatment capacity - reduced Gulping

Liquid Effluent (Gulping) Effluent Separated Solids (Sludge)

Existing Settler New additional Conical Settlers May 2012

Sealer Recycling and

Application (2012)

Paint Shop

Bell Bell Application

(2013)

Paint Shop

Paint Mix Waste

(2013)

Paint Shop

Migration Projects 2012/2013

1. Sealer Recycling Project

2. Application Optimisation

Savings:99.4 tons/annum waste 1.34 tons/annum VOC

New Efficient Paint Spraying Technology

Savings:5.3 tons/annum Waste, 3.4 tons/annum VOC

Facility change to treat and remove additional paint waste.

Savings:

94 tons/annum Waste

Hydraulic Powerpacks

(2012)

Engine Plant

Cooling Towers

(2012)

Body Shop

Cooling Towers

(2013)

Body Shop


Timers fitted onto hydraulic powerpacks to switch off during

weekends.

Savings:105 MWh/annum

108 tons CO2/annum

Cooling Towers switched off during weekends by technicians.

Savings:

346 MWh/annum 355 tons CO2/annum

Variable speed drives installed on each of the 55kW fans.

Savings:

116 MWh/annum 119 tons CO2/annum

Latest Press Shop Technology (2012)

Old Press Shop OperationIn normal Start/Stop mode the clutch and

brake operation consumes additional energy

Press Shop

Ecological Factories – New Press Shop

Expected 2014 full Savings:

Electricity: 1282 MWh/annum CO2: 1316 tons/annum

brake operation consumes additional energy

New Press Shop OperationNew Press Line operates with Continuous

Wave Motion including energy efficient

motors – no application of Clutch/ Brake

Reusable Interlayers : Implementation has eliminated cardboard interlayers.


2010 Waste Separation Project started in Production Departments with basic training.

2011 Waste Management Training and Awareness strategy was developed.

Waste Separation Project rolled out in all production departments

2012 Additional compartmentalised trolleys provided and labelled per waste type.

Project scope extended to office areas for implementation

Think Blue. Factory. Waste Separation

Project scope extended to office areas for implementation

2013 Waste Management Contract Specification created with incentive for Contractor to

increase profit by increased waste separation and recycling.

Think Blue. Factory. Recycle

Identify Opportunities to recycle wherever possible!

SocietyEnergy














supply









New Press Shop



New Press Shop

Title: Solar Thermal supplementing of Water Heating

Supplier: Eisenmann

Savings: 0.017 MWh/unit

Project Description

Solar Thermal Project

Solar thermal panels for Factory Roof Installation :

• The hot water requirements of the existing pre-treatment shall be supported by a solar system

• LPG Savings PS2 : 132 608 kg First Year

• LPG Savings PE Plant : TBC

Potential Further savings :

Heat pump to further utilise heat and reduce Chiller Electrical Consumption

Project Description

SocietyEnergy














supply









New Press Shop



New Press Shop

E-Learning Modules

772 People have completed the module (Sep 2013)

Internal Communication

Show of Hands – Employee Volunteer Programme

2011

• Nonkqubela Primary School

• Orsmond TB Hospital

• Lake Farm Alien Vegetation Project

2012

Employee Volunteerism

2012

• Siyaphambili Pre Primary School

• SOS Children's Home

• Limekhaya High School

• South African Marine Rehabilitation and Education 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

2012 Top Green Organisation AwardInstitute of Waste Management of Southern Africa, in association with the

Eastern Cape Department of Economic Development and Environmental Affairs

The competition focused on organisations’ excellence and innovation

practices in managing and improving air quality, biodiversity, energy

efficiency, water usage and waste issues.

Think Blue. Factory – Awards

2012 Exporter Club Environmental Award

The company’s drive to reduce its carbon footprint with

implementation of new Technologies, employee awareness,

Measurement systems and programs to reduce the use resources.

We can – Can you? Think Blue.

Thank You

topic : think blue. factory at vwsa vwsa thinkblue factory... · 2020-01-27 · ecological...

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