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TRANSCRIPT
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
SocietyEnergy
supplyEmployeesEfficiency
Four Focus Areas
Make Ecological production transparent
Green Building Certification
Sponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO Mile
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
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
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
Combine environmental protection & economics by utilizing resources efficiently in the factory
TB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste Stream Management
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
supplyEmployeesEfficiency
Make Ecological production transparent
Green Building Certification
Sponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO Mile
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
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
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
Combine environmental protection & economics by utilizing resources efficiently in the factory
TB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste Stream Management
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
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
Migration Projects 2012/2013
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.
Migration Projects 2012/2013
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.
SocietyEnergy
supplyEmployeesEfficiency
Make Ecological production transparent
Green Building Certification
Sponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO Mile
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
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
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
Combine environmental protection & economics by utilizing resources efficiently in the factory
TB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste Stream Management
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
supplyEmployeesEfficiency
Make Ecological production transparent
Green Building Certification
Sponsorships :SAMRECAmarok Rhino ProjectDyer Island ProjectGreat White SharkECO Mile
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
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
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
Combine environmental protection & economics by utilizing resources efficiently in the factory
TB.F. WorkShopsMeasurement / KPI’sEnergy MarshallsBase Load reviewsWaste Stream Management
New Press Shop
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.
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.