gestione energia: iso 50001 ed energy management milano ... · iso 50001 ed energy management...

Gestione Energia:

ISO 50001 ed energy management

Milano, 10 ottobre 2012, Doria Grand Hotel

Property of Comau - Duplication prohibited October 2012

AGENDA

• COMAU

• eCOMAU

• ISO 50001: Green Procurement

• R&D: European Projects

2

Property of Comau - Duplication prohibited October 2012 3

COMAU MISSION

TARGET MARKET:

AUTOMOTIVE SECTOR

AND INDUSTRIES REQUIRING

PROCESS

AUTOMATION SOLUTIONS

COMAU IS A GLOBAL AND INNOVATIVE

PROVIDER OF SUSTAINABLE AUTOMATION

AND SERVICE SOLUTIONS

BASED UPON COMAU

TECHNOLOGICAL KNOW-HOW

AND EXPERIENCE


FIGURES

ONE TEAM

MORE THAN 35 YEARS OF EXPERIENCE

5 RESEARCH & DEVELOPMENT CENTERS

14 MANUFACTURING PLANTS

23 OPERATIVE CENTERS

13 COUNTRIES

102 PMI® CERTIFIED PROJECT MANAGERS

14,500 EMPLOYEES WORLDWIDE

11,000 EMPLOYEES IN EMERGING COUNTRIES


REFERENCES

AEROSPACE

AUTOMOTIVE

ENERGY

HEAVY INDUSTRY

PUBLIC TRANSPORTATION

RECREATIONAL

DEFENSE

http://www.deere.com/


COMAU GROUP ORGANIZATION

CROSS FUNCTIONS

ENERGY MANAGEMENT TEAM

PROJECT MANAGEMENT OFFICE

INDUSTRIAL OPERATIONS

BODY WELDING

POWERTRAIN SYSTEMS

ROBOTICS

AEROSPACE

SERVICE

BUSINESS UNITS

ADAPTIVE SOLUTIONS

QUALITY

BRIC PRESENCE

WE WORK DIRECTLY WITH CUSTOMERS IN THEIR AREA, FOCUSING ON THEIR REQUIREMENTS

AND TAILORING ALL COMAU PRODUCTS, SOLUTIONS AND SERVICES TO THE SPECIFIC LOCAL NEEDS


®

Services - Green Automation Consulting

COMAU DEVOTES SIGNIFICANT RESOURCES TO TURN

THE GREEN-COMMITMENT AND

ENVIRONMENTAL SUSTAINABILITY

INTO REAL ENERGY SAVING RESULTS,

DEVELOPING SHORT TERM PAYBACK

GREEN AUTOMATION SOLUTIONS

IN MATERIAL HANDLING, WELDING,

METAL CUTTING AND ASSEMBLY SYSTEMS

COMAU ALSO OFFERS GREEN-FIT® CONSULTANCY

ON EXISTING MANUFACTURING SYSTEMS


THE MARKET: “AN UNEXPLOITED OPPORTUNITY”

(source Susi Partners)

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Improving energy efficiency is key to reducing greenhouse gases

Development of global potential for

energy efficiency improvements1

European energy consumption and

savings potential by 20202

• Energy Efficiency is biggest lever for

reducing global greenhouse gases

• EU has significant potential for energy

savings, especially in buildings.

Source: 1 Eco-efficiency. Chapter 6 – Environmental performance of constructions

2 Communication from the European Commission: Action Plan for Energy: Realising the potential 2006 Efficiency


DETROIT TURIN

eCOMAU NETWORK

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SHANGHAI SÃO PAULO BIELSKO BIALA


BUSINESS MODEL: ENERGY EFFICIENCY FOR MANUFACTURING

“PLUG & SAVE" ON PROPRIETARY SOLUTIONS

• Comau Robotics: robots equipped with C5G Control Unit

• Comau Powertrain: Smart Drive, Urane

• Comau Body Welding: Versaroll

YOUR ENERGY MANAGEMENT

IN GOOD HANDS

• Industrial Energy Managers

• Utilities management for all kind of industries

IMPROVEMENT OF MANUFACTURING

PROCESSES IN EE PERSPECTIVE

•Industrial Energy Managers

•Product / Process experts focused on sustainable design,

Green-FitTM, LCC Analysis

•Green manufacturing

•Green procurement

•Funding & Incentives

Consulting Service

Green Products & Technologies

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NON PROPRIETARY SOLUTIONS

• Buildings (heating, cooling, lightning monitoring

systems…)

• Painting systems

• Trigeneration / Cogeneration


CONSULTING FOR INDUSTRIAL PROCESSES

Analysis of data

(electricity, compressed

air, water, …)

1 2 3 4 5

Implementation of

measuring systems

Proposal of energy

efficiency actions

Simulation

Implementation &

monitoring of energy

efficiency solutions

eCOMAU‘s five steps of energy efficiency consulting process

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ENERGY CONSUMPTION MIX…

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IN AUTOMOTIVE MANUFACTURING PER INDUSTRIAL SECTORS (EU27)

Source: European Environment Agency - 2009

AUTOMOTIVE SECTOR:

• Average Energy Consumption

• Weight Vs Process


eCOMAU FOR THE AUTOMOTIVE INDUSTRY


EMISSIONS / WASTE FROM CAR MANUFACTURING

Body Parts

Raw material

Stamping/ Molding

Machining

Surface Treatment

Welding

Painting

Sealers & Adhesives

Powertrain

Casting Machining

Components

Manufacturing Painting

Air emissions

Solid waste

Waste water

Oil waste

Oil mist

Scrap

FINAL ASSEMBLY

Raw material

Raw material


GREEN-FITTM

RETROFIT activity focused on energy saving for all

manufacturing automated processes

Robotics Painting BW Machining

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PAINTING

LINES

ITALY

CNC

ITALY & POLAND

TRANSFER

LINES

ITALY & POLAND

ROI < 2

YEARS

< 2

YEARS

< 2

YEARS

ROBOTICS

ITALY

> 2

YEARS

CASE STUDIES - PROCESS ENERGY EFFICIENCY

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MACHINING CENTERS

NB: data refer to 92 COMAU 1GXL machining centers

Machining electrospindle with

axes driven by ball screws with

horizontal electrospindle

• single spindle

• twin spindle center

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Process: Machining

Description: Installation of monitoring systems and Green-FitTM

Yearly energy saving equivalent 1.537.359 kWh (3 shifts)

Reduction of CO2 emissions: 999.283 Kg

ROI: < 2 years


ISO 50001: IL COINVOLGIMENTO DEI FORNITORI

Oggetto: politica energetica

Comau è impegnata nella gestione responsabile ed efficiente dell’energia di tutte le sue attività: sviluppo prodotto, progettazione, approvvigionamento, realizzazione ed installazione dei propri sistemi di automazione industriale.

Consapevole dell’esigenza, a livello mondiale, di una maggiore sostenibilità ambientale, Comau intende perseguire il miglioramento continuo della propria performance energetica e la conseguente riduzione delle emissioni di gas serra, in piena coerenza con i valori e le politiche di Fiat Group. Nell’ottica di garantire tale obiettivo, Comau è impegnata nell’implementazione e mantenimento di un Sistema di Gestione per l’Energia per tutti i propri siti produttivi, in conformità allo standard internazionale ISO 50001:2011.

Il Sistema si basa sui seguenti principi: •Sostenibilità ambientale •Miglioramento continuo della prestazione energetica •Identificazione ed utilizzo di indicatori di performance, che verifichino il raggiungimento dell’obiettivo

•Sensibilizzazione dei propri fornitori sui temi dell’efficienza energetica •Rispetto degli obblighi legislativi La responsabilità nella gestione energetica riguarda l’intera organizzazione, conformemente alla specifica mansione e competenza di ogni singolo lavoratore.

A tal fine, l’organizzazione definisce e comunica la politica energetica, gli obiettivi di risparmio energetico, i comportamenti attesi ed i relativi programmi di attuazione. Comau mette a disposizione tutte le risorse necessarie ad attuare e controllare il sistema per il raggiungimento degli obiettivi stabiliti, nonché a formare, sensibilizzare e render consapevoli i propri dipendenti.


A.5.7 Procurement of energy services, products and equipment

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A.5.7.1 Procurement of energy services and products

Procurement is an opportunity to improve energy performance through the use of more

efficient products and services. It is also an opportunity to work with the supply chain and

influence its energy behaviors.

The applicability of energy purchasing specifications may vary from market to market.

Energy purchasing specification elements could include energy quality, availability, cost structure,

environmental impact and renewable sources.

C5G : next generation Robot Control Unit


Urane – SD: Energy Saving features

Micro filtered air automatically closed after 30 minutes production break

(new valve)

Hydraulic system motor automatically stopped during production break

Coolant pump inverter managed, variable speed for different tools

Motor automatically stopped when HP is not required (part change, tool

change, stop production, ..)

Exchanger fan switch-off when internal temperature is under 30 degrees

Axis automatic standby mode during part change and production break

Machine sleeping mode during stop production (power-off machine)


Integrated dressing from the base to the flange of the

robot

Parallelogram structure with no balancing mass

Perfect symmetry of the mechanical structure

Strong, agile and streamlined kinematic structure

Reduction in cycle-time

Low power consumption

Reduced footprint

Possibility of installation both on floor and ceiling

100% off-line programming

2 versions available: Standard and Shelf

HIGH PAYLOAD ROBOTS

Focus on Smart NJ4 “Hollow Wrist”: all the advantages of a revolutionary project


High processing power

the C5G uses the latest generation of industrial PC’s APC820

with Core 2 Duo technology CPU which is capable to obtain

high performances with low energetic consumption

Modular system for drives unit and I/O

Modular system for drives up to 9 or 10 axis in the base cabinet

function of the power

Compact dimensions

800x500x1100 mm

Free and ergonomic space for application functions integration

Energy saving system

Lowest consumption in stand by. Low consumption during

operations

Cooling system proportional to the level of the Control Unit’s

operations

Energy network recover system with program of high dynamic

content

C5G Control Unit

C5G : next generation Robot Control Unit


Launched in 2012, this project is funded by Torino Chamber of Commerce and managed by Piemonte

Agency.

It gathers 40 local companies working in: Energy, Waste, Water, Air and Noise reduction, Research &

Consulting, Renewable Energies, Photovoltaic and Thermal solar, Biobuilding, Biomasses,

Cogeneration, Wind, Geothermal.

Run in collaboration with the key players, small or medium companies, research centres and international

operators locally based.

Aims at:

Enhancing Environment & Energy companies’ technological competences

Promoting Piedmontese excellences in the enviornmental sector abroad

Enabling the sector’s growth, through individual or clustered actions

Finding new buyers or commercial partners abroad

Boosting business internationalization know-how.

For more information [email protected]

RESEARCH & DEVELOPMENT


EMC2-Factory

Title: EMC2-Factory

Eco Manufactured transportation means from Clean and Competitive Factory

Funding Agency: European Commission - FP7-NMP-FoF-2011-1

Funding Scheme: Collaborative Projects - Large-scale Project

Main Objectives: Cleaner and more resource-efficient production in manufacturing, aiming at increasing the overall production systems efficiency:

• by decrease in the use of resources and energy

• in emissions and waste treatment

• recycling at the point of use

Expected Results: Sustainable manufacturing solutions in automotive,

aeronautical and railway production systems

Timetable: 2011 – 2014 (36 months)

Partners: CRF (I), COMAU (I), CNR-ITIA (IT), PoliMI (I), Siemens CT (DE), TUD PTW (DE), TUB IWF (DE), Festo (DE), Siemens TO (AU), TWI (UK), Senseor (FR), TNO (NL), CECIMO (BE), Tecnalia (ES), Correa (ES), SPASA (ES), AIUT (PL)


PLANTCOCKPIT

Title: PlantCockpit

Production logistics and sustainability cockpit

Funding Agency: European Commission - FP7-2010-NMP-ICT-FoF

Funding Scheme: Large-scale Integrating Project (CP-IP)

Main Objectives: Development of a central environment for monitoring and control of all intra-logistical processes in order to improve production management, process efficiency and optimize resource utilization. This will provide a holistic visibility of the plant, the current status, bottlenecks, deviations and exceptions. This will be achieved by defining standard interfaces and a reference model for integrating the most prominent manufacturing processes.

Expected Results: The project will realize an integrated heterogeneous, multi-vendor system landscapes including ERP, MES, SCADA, condition-based maintenance, energy management, and other special-purpose systems. The project will impact on lead time, purchasing processes, better energy/resources management and overall efficiency of processes.

Timetable: 2010 – 2013 (36 months)

Partners: SAP (D), COMAU (I), PoliMI (I), Acciona (E), BMW (D), Doehler (NL), EPFL (CH), Fatronik (E), Iconics (CZ), Intel (IRL), TUT (FIN), UniDresden (D)


COMAU S.P.A.

VIA RIVALTA,30

10095 GRUGLIASCO (TO)

ITALY

TEL. +39 011 0049111

www.e.comau.com

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Ing. Paolo Segreto

eCOMAU Sales & Marketing

Energy Manager Comau Grugliasco

gestione energia: iso 50001 ed energy management milano ... · iso 50001 ed energy management...

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