Dipl.-Ing. Phillip Karcher. Division Quality Management Fraunhofer-Institute for Production Systems and Design Technology IPK, Berlin

Transcription

1 Research Study: Success Factors and Organizational Approaches for the Implementation and Operational Use of Energy Management Systems according to DIN EN ISO Division Quality Management Fraunhofer-Institute for Production Systems and Design Technology IPK, Berlin Prof. Roland Jochem Head of the Division Quality Management Fraunhofer-Institute for Production Systems and Design Technology IPK, Berlin

2 Content Introduction to Fraunhofer Organization Process and Goal Participants ISO Successful Implementation of a certified EnMS Pursued goals after Certification Internal Communication and Organization Measures The Energy Management Team (EnM-Team) 2 / 31

3 Fraunhofer-Gesellschaft Profile - Europe s largest research organization 7 Groups Information and Communication Technology Light & Surfaces Life Sciences Microelectronics Production Defence and Security Materials and Components 80 Institutes worldwide 60 Institutes in Germany employees 2 billion annual research budget 3 / 31

4 Fraunhofer Organization - Locations in Germany 60 institutes at 40 locations in Germany Itzehoe Bremen Hannover Berlin Braunschweig Golm Oberhausen Magdeburg Dortmund Duisburg Schmallenberg Aachen St. Augustin LeipzigDresden Euskirchen Jena Ilmenau Chemnitz Darmstadt Kaiserslautern St. Ingbert Saarbrücken Pfinztal Karlsruhe Stuttgart Freiburg Würzburg Erlangen Freising 4 / 31

5 Fraunhofer Organization - Research Units Worldwide 5 / 31

6 Production Technology Center - Mission and Goals applied research and development Optimization of industrial processes from the product idea through to product development, design and manufacture Fast transfer of R&D results into practical applications Cost-effective and environmentally friendly solutions for SME Innovations for Industry 6 / 31

7 Production Technology Center - Overview Fraunhofer Gesellschaft Institute for Production Systems and Design Technology (IPK) University of Technology Berlin Institute for Machine Tools and Factory Management (IWF) Corporate Management Prof. Dr.-Ing. H. Kohl Virtual Product Creation Prof. Dr.-Ing. R. Stark Production Systems Prof. Dr. h. c. Dr.-Ing. E. Uhlmann Automation Technology Prof. Dr.-Ing. J. Krüger Joining and Coating Technology Prof. Dr.-Ing. Michael Rethmeier Quality Management Prof. Dr.-Ing. R. Jochem Medical Technology Prof. Dr.-Ing. E. Keeve Assembly Technology and Factory Management Prof. Dr.-Ing. G. Seliger Industrial Information Technology Prof. Dr.-Ing. R. Stark Machine Tools and Manufacturing Technology Prof. Dr. h. c. Dr.-Ing. E. Uhlmann Industrial Automation Technology Prof. Dr.-Ing. J. Krüger Joining and Coating Technology Temporary Administration: Prof. Dr.-Ing. R. Stark Quality Science Prof. Dr.-Ing. R. Jochem 7 / 31

8 Quality Management Services Quality excellence Continual improvement processes (CIP) Total quality management (TQM) Value added in quality management Quality assurance Quality stream analysis Quality systems, methods, evaluation und organization Energy Management 8 / 31

9 The EnMS-Study 9 / 31

10 Process and Goal of the EnMS Study Defined goal of this market research is the communication of a successful approach during the implementation of an EnMS. It observes German companies, which implemented the EnMS according DIN EN ISO into their organizational structure and operational organization. It additionally communicates realized measures and the knowledge gained within the project. Communication of a successful approach during the implementation of an EnMS 10 / 31

11 Participants 1263 certified companies were contacted Response rate of 9,5%, this is equivalent to 121 sets of answers 51% SME 53% with a annual revenue of more than 50 Mio. Euro 84% manufacturing industry Enterprise size according to number of employees Enterprise size according to annual revenue Distribution of the surveyed companies 22% 16% 2% 5% 1% 4% 3% 31% 8% 4% 4% 51% 53% 43% 4% 11% 6% >1000 < > 50 Mio Mio. 1-5 Mio Mio. 10% 16% 11 / 31

12 ISO / 31

13 ISO Overview The purpose of this international standard is to enable organizations to establish the systems and processes necessary to improve energy performance, including energy efficiency and intensity. [DIN EN ISO 50001] Successor of EN Similar structure like other management system norms PDCA-Cycle Responsibility and performance Nomination of a management representative and building of an EnM-team 13 / 31

14 ISO Certification process Selection of an accredited certifying company Contract negotiation and commissioning Coordination of dates and audit planning Pre-audit (optional) Certification audit Nonconformity management and correction measures (if required) Decision about issuance of certificates Certificates (valid 3 years) Annual surveillance audits Re-certification (after 3 years) 14 / 31

15 ISO Duration to the Certification Estimated duration to the Certification Variance of the actual compared to the proposed duration 38% scheduled exactly 6 months for the implementation 75% accomplished their goal with a delay of only 10% 15 / 31

16 Successful Implementation and goals of a certified EnMS 16 / 31

17 Implementation of a certified EnMS - Goals and Measures to be successful Conducting regular to be as is comparisons Use of existing team structures Clear definition of responsibilities Documentation of business processes Clear formulation of company goals Cost efficient certification Easy integration into an existing management system Goals Regular monitoring of project progress Training of employees Fast certification process Pass certification at the first go Success factor Measure 17 / 31

18 Pursued goals after Certification Goals for the operation of an EnMS according to ISO Reduction of energy-costs is in the first place for all participants 18 / 31

19 Reduction of energy-costs - Realized technical measures Realized technical measures for the reduction of energy-costs 27% more technical measures conducted compared to economic measures Optimization of lighting equipment most common 19 / 31

20 Reduction of energy-costs - Realized economical measures Realized economical measures for the reduction of energy-costs Contrary to technical measures, economic measures can lead to significant cost reduction without the need of high investments 20 / 31

21 How is the EnMS communicated and organized internally? 21 / 31

22 Internal communication - Measures to increase internal acceptance of EnMS Measures to increase acceptance of EnMS by employees ISO requires awareness of the energy policy of all employees 22 / 31

23 Organizational Measures - Overview ISO requires: responsibility and commitment of top management (providing technical, financial, labor resources) Formation of an EnM-Team (to improve energy-related performance of the company) Various ways of integrating EnM into existing organization structure: Functional Organization Division Organization Integration Organization Minimum Organization Posch (2011) 23 / 31

24 Organizational Measures - Types of integration and their evaluation Chosen type of integration Evaluation of chosen type of integration 52% functional organization (staff organization), assessed good or very good by 91% 24 / 31

25 The Energy Management Team - Administration and Composition Administration of the EnM-Team Responsibility for team building Top Management has great influence on team building high priority of this topic as demanded by ISO / 31

26 The Energy Management Team - Members of different Departments Departments to provide team members Primarily technical experts needed 26 / 31

27 Conclusion 27 / 31

28 Conclusion Integration of ISO in existing MS is apparently easy Potential cost reduction due to economic measures is not completely exhausted Only 6% use legal advice in order to reduce taxes Support of government is a big motivation for most organizations 93% of the companies employ an Energy Management Team Companies see vital importance in the implementation process Study is a good basis for future research work Quality assurance in energy consulting Modular energy management systems 28 / 31

29 Contact Division Quality Management Fraunhofer-Institute for Production Systems and Design Technology IPK, Berli Pascalstraße 8-9 I Berlin Phone / Fax phillip.karcher@ipk.fraunhofer.de energiemanagement@ipk.fraunhofer.de 30 / 31

30 References Posch, W. (2011). Ganzheitliches Energiemanagement für Industriebetriebe (1 Edition). (P. D. Bauer, P. D. Biedermann, & P. D. Wohinz, Hrsg.) Wiesbaden: Gabler Verlag Springer. 31 / 31