Environmental Statement. Report Environmental Protection and Safety. Location LuK Savaria Update

Transcription

1 Environmental Statement Report Environmental Protection and Safety Location LuK Savaria 214 Update Status October 214

2 Introduction In the year 212 the environmental management at LuK Savaria has been reviewed according to the actual EMAS regulation (EC No. 1221/29) and the environmental statement 212 has been validated. The site registration of Schaeffler plants is carried out by the Chamber of Commerce in Nuremberg in Germany as a group registration. LuK Savaria is covered under the group registration with the register number DE The present actualised environmental statement, according to requirements of the EMAS III (regulation (EC) Nr. 1221/29), is integral part of the environmental statement 212 and describes the relevant changes, the development of key performance indicators as well as the status of environmental objectives and targets of the plant. Main changes of LuK Savaria Technology, machines LuK Savaria, Plant 3B, Stamping production received 4 cutting machines during summer time, 213. CRS (clutch release system) segment of ZMS (double mass flywheel) production has moved to a special, separated, high cleanness production room at the end of the previous year. CRS has been manufacturing since August, 212. and is looking forward to additional improvements in the near future. Mainly KS-KD and XSG production uses the so called just in time Kanban roll racking system. A pull electric trolley infrastructure is being introduced to Kanban, transporting raw material and semi-finished goods in KLT packing units from the storehouse to the destination of use. Cutting production has also improved from autumn, 213 on: DK (double clutch cutting) capacity has increased and CVT-Nabe sector has developed visibly. There is a new technology KS Nabe in cutting segment, starting its operation with 1 machine in June, 214. Building, facility At the end of 213. LuK Savaria purchased the neighbouring TISzK / Inkubator office block. There are significant indoor reconstructions there.

3 Organisational A new generation of shift supervisors have been introduced in the frame of teamleader concept. There is a new H&S engineer in the E&S team since February, 214, there are 4 people to coordinate environmental and safety issues. Fire safety Fire safety responsibility is being coordinated by E&S team. There is a fire safety advisor and some special companies to support fire safety operative tasks. At the moment TISzK / Inkubator office block reconstruction is ongoing but after the work is finished, fire safety infrastructure will be integrated into Site Fire Safety Manual and Emergency Manual. On the 15th of May, Regional Catastrophy Authority officers arrived to LuK Savaria to participate in an authority officers practical training (photo5). Our factory has several best practice solutions (fire resistant structures, gates, doors, operating mechanisms), authority people were studying these good examples. Occupational safety Number of occupational work accidents with > 3 days has decreased (for the first time compared to previous years). Number of first aid level occupational work accidents and the total number of registered occupational work accidents have increased. We managed to achieve the target set (accident frequency rate < 17) first time success compared to previous years.

4 Accident figures tend towards a bad direction in 214. Our factory grows dynamically: capacity increases, new machines arrive and headcount improves significantly. A short term Health & Safety strategy was worked out in 214, to get number of injuries and statistics figures down. Numbers of accidents Accident frequency rate Occupational health In 213 a new direction was defined in developing our occupational health service. According to a modified contract, the on site occupational health doctor works 6 hours a workday (instead of the previous 5 hours per workday) and this attendance can be further improved. To improve our past approach (following health management through action plans), a Health Care Strategy has been developed in the beginning of 214. The 3 pillars of this perspective are Prevention, Illness management and Rehab activities. Each pillar has several projects behind, realisation is ongoing in 214. LuK Savaria distributed Dr. Card health cards as a gift for own employees in January, 214. Dr. Card health card means special health service and health related service price discounts for people.

5 Objectives and targets Our Achievements Environmental targets Environmental Program Status Actions Improve waste management >> Develop new waste island and collection method New selective waste island structure is complete, new shipment method is working, there is a modified contract with waste handling partner, only ZMS and Cutting (FZ) segments have minor improvements ongoing Hand dryers replacing paper towels Get electricity from a safer source Construction of a methanol supply system >> Decrease high cost and waste generative paper towels to a cost and energy efficient solution >> Our main electrical input stream gets energy from an out of city network >> Upgrade current IBC container location with a modern tank technology The project cannot be implemented everywhere in the factory but is being introduced widely The complex loaded city network has been changed to a more stable out of city electrical source Planning and design phase complete, the project is waiting for realisation Goal has been achieved. Part of goal has been achieved. Additional actions planned. Goal not achieved. Planning Environmental targets Environmental Program Responsible Deadline Construction of a methanol supply system Improve energy management >> Upgrade current IBC container location with a modern tank technology >> 8 % of tasks in EnEffPro summary must be completed Heat treatment segment manager Maintenance manager Improve waste management >> Construct a new waste handling yard Maintenance manager Improve cooling water usage efficiency Replace fork lift trucks with mechanised pull trucks >> Improve current cooling station (cooling tower solution was modified) >> Higher risk and less economic forklift trucks planned to be replaced by smaller size, more economic mechanised pull trucks Maintenance manager Logistics manager MOVE manager

6 Key Indicators Per EMAS III Szombathely Absolute Relative* Database Reference data Added value in Mio. Euro [Mio] General Data Total headcount [MA] 1,7 1,757 2,15 Size of property [m 2 ] 146, , ,22 Total sealed surface [m 2 ] 54,99 73,45 18,233 1,21 1,365 1,582 [m 2 / Mio ] Biodiversity [%] Input Water [m 3 ] 75,41 84,665 11,989 1,638 1,574 1,491 [m 3 / Mio ] Electricity [kwh] 27,374,657 3,45,482 37,21,29 597,7 565, ,9 [kwh/ Mio ] >> Amount of electricity from renewable energy (only external supply) [kwh] 1,916,226 2,131,534 2,64,715 41,839 39,62 38,81 [kwh/ Mio ] >> Amount of electricity generated inhouse (conventional) [kwh] [kwh/ Mio ] >> Amount of electricity generated inhouse from renewable energy [kwh] [kwh/ Mio ] >> Percentage of renewable energy with regard to overall consumption [%] Natural gas [kwh] 7,351,356 1,59,773 12,169,444 16,51 186, ,916 [kwh/ Mio ] >> Amount from renewable energies [kwh] [kwh/ Mio ] >> Percentage of renewable energies [%]... Light fuel oil [l] [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] >> Percentage of renewable energies [%]... Fuels for internal logistics Diesel [l] 4,381 32,566 31, [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] >> Percentage of renewable energies [%]... Gasoline [l] [l/ Mio ] >> Amount from renewable energies [l] [l/ Mio ] >> Percentage of renewable energies [%]... District heating [kwh] [kwh/ Mio ] >> Amount from renewable energies [kwh] [kwh/ Mio ] >> Percentage of renewable energies [%]... Propane / LPG [kg] [kg/ Mio ] Methanol [kg] 16,8 41,6 75, ,99 [kg/ Mio ] Energy input [kwh] 35,215,4 41,56,399 5,99, , ,13 732,446 [kwh/ Mio ] >> Amount of renewable energy with regard to total energy input [kwh] 1,916,226 2,131,534 2,64,715 41,839 39,62 38,81 [kwh/ Mio ] >> Percentage of renewable energy with regard to total energy input [%]

7 Absolute Relative* Database Emulsion concentrates [kg] 3, 33, 37, [kg/ Mio ] Processing oils [kg] 4,18 5,368 11, [kg/ Mio ] Solvent - VOC [kg] [kg/ Mio ] Solvent - Non-VOC [kg] 1, [kg/ Mio ] Metal raw materials [t] [t/ Mio ] Metal semi finished products (external supply) [kg] 35,911 33,75 4, [kg/ Mio ] Other raw materials [kg] 537, 51, , [kg/ Mio ] Output Waste [t] 13,653 13,58 17, [t/ Mio ] non hazardous waste [t] 1,18 1,5 1, [t/ Mio ] >> paper, cardboard [t] [t/ Mio ] >> waste wood [t] [t/ Mio ] >> domestic waste [t] [t/ Mio ] >> others [t] [t/ Mio ] hazardous waste [t] [t/ Mio ] >> grinding swarf / sludge [t] [t/ Mio ] >> waste emulsion [t] [t/ Mio ] >> waste oil [t] [t/ Mio ] >> others [t] [t/ Mio ] Scrap (ferrous + non-ferrous) [t] 12,424 12,258 16, [t/ Mio ] CO2-equivalents [t] 17,46 16,665 18, [t/ Mio ] >> CO2-emissions from combustion processes at this site [t] 1,611 2,171 2, [t/ Mio ] >> CO2-emissions from electricity obtained from external sources [t] 15,795 14,494 15, [t/ Mio ] >> CO2-emission factor per kwh electricity obtained from external sources [g/ kwh] >> CO2-emissions from district heating obtained from external sources [t] [t/ Mio ] >> CO2-equivalent from the refrigerant agent amounts refilled due to leakages [kg] [kg/ Mio ] SO2 - emissions from combustion processes at the site [kg] [kg/ Mio ] NOx - emissions from combustion processes at the site [kg] , [kg/ Mio ] Particulate mater emissions [kg] 1,333 1,485 1, [kg/ Mio ] >> from combustion processes at the site [kg] [kg/ Mio ] >> from production an other processes [kg] 1,33 1,482 1, [kg/ Mio ] VOC-emissions [kg] [kg/ Mio ] * In relation to added value Sources for evaluation of emission factors are the ProBas data bank ( - status: September 22nd, 211) as well as the GEMIS 4.8 data bank (

8 Input Notes on selected key performance indicators Electricity consumption Electricity consumption has risen compared to previous years. This occurence can be explained with growing machine park and Plant 3B machine startup and trial run. The added value based specific data show a positive tendency. Plant 3B receives additional new machinery and technology, its final structure becomes stable at the end of 215. Gas consumption The reason for the positive, stable line of warm water and heat purpose gas consumption is the 2 compressor waste heat recovery systems. The use of these solution brings savings for the factory even against capacity increases. As for technology gas consumption, it is heat treatment production s 213 dynamism, that shows its impact. In Plant 3B there is a heat treatment machine line (659) working with the existing Etageofen. These changes explain the tendency on the graph. Water consumption Water consumption quantity changes follow the increased headcount and Plant 3B technology increase with significant water demand machinery. The specific water consumption seem to be stable. The slight increase of the specific value can be explained with trial runs in 213 and obligatory liquid release from and fill up of machines that participate any relocation process. [kwh] Electrical consumption and specific value [kwh / mio ] 4,, 61, 35,, 6, 59, 3,, 58, 25,, 57, 2,, 56, 15,, 55, 54, 1,, 53, 5,, 52, 51, Electricity kwh kwh / mio [m 3 ] Gas consumption 6, 5, 4, 3, 2, 1, Heating m 3 Technology m 3 [m 3 ] Water consumption and specific value [m 3 / person] 12, 8 1, 8, 6, 6 4 4, 2, 2 Water m m 3 / person

9 Output Notes on selected key performance indicators [kg / t] Non hazardous waste Waste economy Non hazardous waste of our site are: metal waste, packaging material waste and communal waste. The rise of specific value compared to production quantity can be explained with technology modifications and trial runs, plus the large waste project ongoing through the year 213. A positive tendency can be expected from 214 on kg non hazardous waste / t produced [kg / t] Hazardous waste kg hazardous waste / t produced [t CO2] CO 2 emission The specific value of hazardous waste compared to production quantity has increased in 213. Machine relocations required several cooling-lubricant station to move and before any significant change, the circulation equipment solution must be released and refilled after final (re)installation. The hazardous waste quantity generated caused larger amounts to be managed. Additional reason is cleaning activity precaution measures to protect our waste water pipeline network: the polluted washing water has been collected in separated containers and managed as hazardous waste to spare our waste water infrastructure (Plant 3B has significant surface and influence to cleaning activities). Air pollution protection Emission parameters of our boilers, gas operated heat treatment machines and other burning technology equipment stay safely below end values defined by the environmental authority. Our carbon-dioxide values and ratio are acceptable. 18, 16, 14, 12, 1, 8, 6, 4, 2, t CO2 emissions from electricity obtained from external sources t CO2 emissions from combustion processes at the site

10 Environmental Verifier s Statement Verifier s Declaration The undersigned, Dr.-Ing. Norbert Hiller, EMAS Environmental Verifier, registration number DE-V-21, accredited and authorized for the area designated by NACE Code 29.32, confirms that his inspection of the site at Zanati u. 31., 97 Szombathely has met all of the requirements stipulated by Regulation (EC) No /29 of the European Parliament and Council dated November 25, 29 on the voluntary participation of organizations in an environmental management and audit scheme (EMAS) as indicated in the updated environmental statement (report entitled Environmental Protection and Occupational Safety ) of by LuK Savaria Kft., registration number D The signatures at the end of this statement confirm that >> The inspection and validation have been completed in full agreement with the requirements stipulated in (EU) Regulation No /29 >> The result of the inspection and validation confirms that no evidence of non-compliance with valid environmental specifications has been found >> The data and information in the environmental statement (report entitled Environmental Protection and Occupational Safety ) for the site at Zanati u. 31., 97 Szombathely as part of LuK Savaria Kft. represent a reliable, credible and true picture of all activities at this site within the area indicated in the environmental statement. This statement cannot be equated to an EMAS registration. EMAS registration can be completed only by an authorized agency in accordance with Regulation (EC) No /29. This statement must not be used as an independent basis for informing the public. Dr.-Ing. Norbert Hiller LuK Savaria Kft., Questions about environmental protection Questions about environmental protection and and safety at the location: safety at Schaeffler: LuK Savaria Kft. Tamás István Norbert Hörauf Zanati u. 31. Industriestraße Szombathely 9174 Herzogenaurach Internet Internet tamas.istvan@schaeffler.com Norbert.Hoerauf@Schaeffler.com From Hungary: From Germany: Phone Phone Fax Fax From other countries: From other countries: Phone Phone Fax Fax The structure and contents of this report correspond to the requirements stated in Annex IV of Regulation (EC) No /29 of the European Parliament and the Council dated November 25, 29 regarding the voluntary participation of organizations in the eco-management and audit scheme (EMAS). Moreover, the report contains information about issues pertaining to occupational safety, plant security and fire protection as well as general information on social benefits pr ovided by the company and this location. Schaeffler Technologies AG & Co. KG 214, october This publication or parts there of may not be reproduced without our permission. The next consolidated environmental statement will be submitted for validation by August 215. An updated environmental statement is published annually.