Environmental Statement

Transcription

1 Environmental Statement Report Environmental Protection and Occupational Safety LuK (UK) Ltd, Sheffield, England UPDATE Status July 215

2 Introducing the Location in Sheffield Our modern 17.5 m2 plant is located on the Waleswood Industrial Estate in Sheffield, South Yorkshire, which is located close to Junction 31 of the M1 motorway. The locality allows for employment from within, with close proximity to residential areas ensuring low travel distances for commuting. The Company works closely with a number of local training providers to support the business and development of the work force. The plant manufactures a range of passenger and tractor clutches supplying to UK and world-wide vehicle and tractor manufacturers. Environmental protection is part of our management principles. LuK (UK) Ltd is committed to adhering to good environmental protection practices and our contribution of care for the planet. LuK (UK) Ltd is a highly automated and integrated unit of LuK s world-wide manufacturing group, and the plant is amongst the most modern in the country. Our production processes cover machining and assembly. Many of these are computer controlled, and incorporate in-line quality control. The provision of an on site canteen providing a selection of daily meals, is well received by our employees. It is also LuK s policy to develop our own production equipment and processes whenever we can, ensuring we always get maximum benefit from our investment in the latest plant and equipment. This has included a computer controlled tool storage system and new environmental protection systems. The result: LuK is established as a leading supplier to the automotive industry in the UK and through-out the world, with the Sheffield factory being widely recognised for quality of its products and its responsibility to the environment. LuK (UK) Ltd has set up our own Supplier Development Programme to ensure that our total quality performance needs are maintained and our customer demands are met. LuK (UK) Ltd is divided into two production cells: Passenger and Tractor clutch, both are automotive based. The plant is a Tier 1 supplier to major motor manufacturers and has good relations with all its customers providing the support and delivery promise expectations.

3 INTRODUCTION In the year 213 the environmental management at LuK (UK) Ltd has been reviewed according to the actual EMAS III regulation and the environmental statement 213 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 (UK) Ltd is covered under the group registration with the register number DE The present actualized environmental statement, according to requirements of the EMAS III (regulation (EC) Nr /29), is integral part of the environmental statement 213 and describes the relevant changes, the development of key performance indicators as well as the status of environmental objectives and targets of the plant. Legal requirements are checked and reviewed twice a year. Any violations found are corrected immediately. During the reporting period all relevant limits were met. Changes at the Location Workplace Dust Exposure Survey During 214 workplace dust exposure survey was carried out by an external contractor to confirm that we are in compliance with legal requirements. The sampling included static sampling at locations throughout the machining and assembly sections along with personal sampling involving operatives within these sections. The results of the survey indicated that the levels of inhalable dusts was very low, with the highest exposure being for the DC Riveting Machine No. 577 and EK1 with a result of 4.5 % and 4.1 % respectively of the COSHH Trigger Value, (1 mg /m 3 being the Trigger Value). The rest of the results were below 4 % of the Trigger Value. Environmental Incidents There were no major environmental incidents at this site during 214. Environmental A new water interceptor was installed in the 3rd quarter of 213 to replace the existing unit, enabling liquid waste to be disposed of as per our consent to discharge provided by the local water authority. The interceptor was drained and recharged during the second quarter of 214 as part of routine maintenance. Monthly water analysis is carried out by a UKAS accredited company to ensure compliance with the consent to discharge. There are no changes to the consent to discharge in 214.

4 Occupational Health LuK (UK) Ltd provides a fully equipped First Aid room and provisions to the needs of the Company and employs the services of an Occupational Health Nurse through an external contractor. This ensures that the needs of the employees are met. Pre-employment checks as well as ongoing medical checks are conducted for all employees. Those employees who are involved in processes where they are exposed to abnormal conditions i.e. noise, are checked at pre-determined intervals by the Nurse to ensure there are no signs of damage. A new acoustic sound booth has been installed to carry out hearing tests during 213. During the first quarter of 214 a campaign has been run to raise awareness of hearing protection for all employees. Further insulation projects have been carried out in the Quality Assurance Office and the refurbishment of the Production Managers Office during 214. A programme of works has been carried out during 214 for the maintenance of lighting to ensure adequate lighting is maintained throughout the plant. LED light has been installed within the following areas with auto activation to reduce consumption during none occupied times: Works and reception stairwells, Shipping Hall, East elevation canopy area, office kitchenette, shop floor and office WC s. Five electricity sub meters have been installed during the fourth quarter of 214 and will be coupled into the Data Management System (EDMS) during the first quarter of 215, with plans to install a further eight sub meters during 215. Information gained from the sub metering with be used to establish high usage items and develop a plan for opportunity improvement. Legal Compliance Support for legal compliance is provided by Coventry Council who support both Environmental and Safety regulatory changes throughout the year. Health and Safety updates are provided to LuK (UK) Ltd on a six monthly interval and Environmental updates are provided four times per year. Actions from the updates ensure the Company is legally compliant. Environmental Agency provide updates on legislative changes on Climate Change, and Efficiency. Updates are provided electronically via immediately upon new postings on the website. The Company is supported by Untilitywise, providing information on energy supply and Saving Opportunity Scheme Legislation (ESOS). They also provide reporting on the Company s Carbon Reduction Commitment (CRC), Efficiency Scheme.

5 Objectives and Targets Our Achievements Environmental goals Environmental programs Completed Actions Reduce electricity usage through more efficient usage Noise awareness training Manual handling training Fire Warden training Ensure all substances used at LuK (UK) Ltd have HQ approval Air monitoring Increase energy efficiency, reduce consumption and reduce energy losses >> Replacing lighting with more energy efficient systems >> Promoting awareness of electricity usage and encouraging through visual management the shutting down of equipment when not in use >> Monitoring equipment for compressed air leakages, identifying these through a tagging system then fixing the leaks >> Introduce electricity sub metering for monitoring each section of the business where appropriate >> Training to be provided to employees to broaden their awareness to hearing protection >> Employees are to be provided with manual handling training to develop their skills and awareness to handling techniques >> Refresher training is to be provided to Fire Wardens including the use of the EVAC Chair for specific Fire Wardens >> Submit BAFF forms for all substances in use at LuK to HQ for approval (P177) >> Carry out air monitoring to ensure filtration systems are compliant >> Devise a profile of energy usage for each section or line on the factory to identify improvement opportunities for high usage items Efficiency Team Goal achieved. Part of the goal has been achieved. Goal not achieved. Ongoing program of works. Lights in a number of areas have been installed with LED lighting and automatic activation Ongoing Ongoing work. Surveys carried out using an external contractor. Implemented fourth quarter 214 / first quarter 215. Delivered during the first quarter 214 Delivered during the fourth quarter of 214 Delivered during the second quarter 214. Training provided by an external training provider with site specific training provided internally Third Quarter 214 Third Quarter 214 December 215

6 In addition to the Environmental Goals and Programs published in the 212 Environmental Statement, new Targets have been published by the Schaeffler Group. These are: 1. Minimum degree of completion of the energy efficiency measures from EnEffpro: 8 % 2. Elimination of compressed air leaks, establishment of a system of regular monitoring % increase in energy efficiency in terms of electricity consumption (based on added value). 4. Creation of a risk analysis for the energy supply and emergency plans. The Efficiency Team at LuK (UK) Ltd are currently designing programmes and defining measurement systems to ensure these Targets will be achieved throughout 215. Projects include: Planning Environmental goals Environmental programs Responsible Completion Reduce electricity usage through more efficient usage Compressed air Efficiency Reduce Gas Consumption Increase energy efficiency, reduce consumption and reduce energy losses Awareness Training COSHH Awareness Risk Assessment Training Ensure all substances used at LuK (UK) Ltd have HQ approval >> Replacing lighting with more energy efficient systems >> Promoting awareness of electricity usage and encouraging through visual management the shutting down of equipment when not in use >> Monitoring equipment for compressed air leakages, identifying these through a tagging system then fixing the leaks >> Introduce electricity sub metering for monitoring each section of the business where appropriate >> Purchasing of replacement energy efficient motors >> Cost analysis of a second compressor to decrease the compressed air circuit and recuperate heat generation for the BVL wash tank water >> Investigate reclaiming the heat produced from the compressors for warm air heat-er/water heating >> Devise a profile of energy usage for each machine or line on the factory to identify improvement opportunities for high usage items >> Training to be provided to all employees to raise their awareness to ISO 51 and energy saving projects >> Training to be provided to employees to broaden their awareness towards COSHH and GHS >> Section Managers and Team Leaders to be provided with risk assessment training >> Submit BAFF forms for all substances in use at LuK to HQ for approval (P177) Efficiency Team Efficiency Team Efficiency Team Efficiency Team Coordinator Facilities Coordinator Facilities Coordinator Ongoing program of works Ongoing Ongoing, monitoring equipment being sourced to enable more efficient leak surveys to be carried out December 215 Efficiency Team Team First Quarter 215 Training Coordinator Training Coordinator Second/Third Quarter 215 Third Quarter 215 Purchasing Third Quarter 214

7 Key Indicators to EMAS III Sheffield Absolute Relative* Database Reference data Added value in Mio. Euro [Mio] General Data Total headcount [EMP] Size of property [m 2 ] 35, 35, 35, Total sealed surface [m 2 ] 17,5 17,5 17, [m 2 / Mio ] Biodiversity [%] Input Water [m 3 ] 3,661 3,699 5, [m 3 / Mio ] Electricity [kwh] 5,273,112 5,15,356 5,72, , , ,819 [kwh / Mio ] >> Amount of electricity from renewable energy (only external supply) [kwh] 949,16 92, ,19 49,956 5,154 51,288 [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] 1,141,62 1,559,229 2,229,471 6,84 86, ,86 [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] [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 [%] Propan / LPG [kg] 4,284 4,464 4, [kg/ Mio ] Methanol [kg] [kg/ Mio ] input [kwh] 6,469,875 6,632,64 7,357,837 34,52 368,448 48,769 [kwh / Mio ] >> Amount of renewable energy with regard to total energy input [kwh] 949,16 92, ,19 49,956 5,154 51,288 [kwh / Mio ] >> Percentage of renewable energy with regard to total energy input [%]

8 Absolute Relative* Database Emulsion concentrates [kg] 1,254 1,74 1, [kg / Mio ] Processing oils [kg] [kg / Mio ] Solvent - VOC [kg] [kg / Mio ] Solvent - Non-VOC [kg] [kg / Mio ] Metal raw materials [t] [t / Mio ] Metal semi finished products (external supply) [t] 13, 11, 16, [t/ Mio ] Other raw materials [kg] [kg/ Mio ] Output Waste [t] 2,595 2,586 4, [t/ Mio ] non hazardous waste [t] , [t/ Mio ] >> paper, cardboard [t] [t/ Mio ] >> plastic [t] [t/ Mio ] >> waste wood [t] [t/ Mio ] >> aqueous parts washer [t] [t/ Mio ] >> domestic waste [t] [t/ Mio ] >> others [t] 2 6 1, [t/ Mio ] hazardous waste [t] [t/ Mio ] >> grinding swarf / sludge [t] 1.6 [t/ Mio ] >> waste emulsion [t] [t/ Mio ] >> waste oil [t] [t/ Mio ] >> Tennant floor cleaning water [t] [t/ Mio ] >> BVL wash tank [t] [t/ Mio ] >> others [t] [t/ Mio ] Scrap (ferrous + non-ferrous) [t] 2,283 2,329 2, [t/ Mio ] >> metal borings [t] 1,726 1, [t/ Mio ] >> cast iron solids [t] [t/ Mio ] >> mixed steel [t] [t/ Mio ] >> recyclable clutch disk [t] [t/ Mio ] >> others [t] 1 [t/ Mio ] CO 2-equivalents [t] 2,85 2,547 2, [t/ Mio ] >> CO 2-emissions from combustion processes at this site [t] [t/ Mio ] >> CO 2-emissions from electricity obtained from external sources [t] 2,65 2,217 2, [t/ Mio ] >> CO 2-emission factor per kwh electricity obtained from external sources [g/ kwh] >> CO 2-emissions from district heating obtained from external sources [t] [t/ Mio ] >> CO 2-equivalent from the refrigerant agent amounts refilled due to leakages [kg] [kg/ Mio ] SO 2 - emissions from combustion processes at the site [kg] [kg/ Mio ] NO x - emissions from combustion processes at the site [kg] [kg/ Mio ] Particulate mater emissions [kg] [kg/ Mio ] >> from combustion processes at the site [kg] [kg/ Mio ] >> from production an other processes [kg] [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 (

9 Input Gas Consumption The Chart shows the gas consumption at LuK (UK) Ltd over recent years. The gas used within the business is used for heating and hot water for welfare facilities. The heating is entirely dependant upon the weather. Water is heated using condensing boilers which contribute to the reduction in gas usage and therefore reduced energy costs. A new Building Management Systems (BMS) has been installed in December 21. Allowing more defined control of our heating and lighting within the business. This allow us to have smaller sections which can be controlled independently to allow for the minimum resource to be used to provide heating and lighting. There have been some improvements with the insulation of the building through adding insulation materials to a number of offices on outside walls, improving efficiency and comfort to the improved areas. The installation of a vestibule door into one of the large outside factory doors has improved the internal factory temperature control and reduced factory heating requirements and optimising roof space heaters. [kwh / Degree Days] 1, Factor Gas Consumption Linear (Factor) Electricity Consumption The chart shows that the amount of electricity used to make one clutch. There has been a slight increase in the electricity usage for the period 212 to 213. A number of initiatives have been implemented during the time frame to reduce energy usage, i.e. a number of lights have been replaced for more energy efficient units. Various locations through-out the site have been fitted with automatic activation to provide a more efficient usage of the lights during none occupied times. During the 214 /215, the installation of sub monitoring for electricity usage will identify high usage areas. This will enable a more structured approach to the Company s electricity usage and establish a suitable plan of action to reduce consumption. This will also include further upgrades on our lighting. [MWh] 5,7 5,6 5,5 5,4 5,3 5,2 5,1 5, 4,9 4,8 Electricity Consumption [Annual Factor] , Total MWh / year Annual Factor [MWh / Total Parts Produced] Linear (Annual Factor)

10 Water Consumption The graph shows a reduction in water consumption per person. Water is used on site for welfare facilities, floor and pallet cleaning operations. Floor cleaning machines are serviced on a regular basis to ensure they are maintained in an efficient condition. Male cloakrooms are fitted with automatic systems which means that only urinals flush with use, thus providing a more efficient system. [m 3 ] Water Consumption [m 3 / person] 6, 5,5 5, 4,5 4, 3,5 3, 2,5 2, 1,5 1, Consumption [m 3 ] Consumption [m 3 / person] (based on average headcount)

11 Output Ferrous Scrap Waste The supply of casting has changed enabling a higher quality of product to be supplied, thus reducing the amount of waste produced. Waste produced is removed from site by a local scrap metal company to reduce the effect of transportation (use of fossil fuels and costs). The recycled back into the metal industry and provides a revenue stream for LuK. [t] Ferrous Scrap Waste [Mio. / parts] Aqueous parts washer waste is generated from the cleaning and degreasing of machine parts. Waste water from the BVL wash tank and floor cleaning operations is disposed of through the local sewer system via the onsite interceptor and monitored as part of the Trade Effluent Consent to dis-charge Agreement. Waste oily water is removed from site by a waste contractor. [t] Liquid Waste Streams 3, ,5 2, ,5 6 1, Borings Mixed Steel Cast Iron Total Parts Produced Liquid Waste Oil emulsions are used for the machining of a number of our products. Machine filtration enables the fluid to be recycled to maximise the usage of the fluid. A new EMAG machine as been installed part way through 213, enabling a high percentage of our product to be dry machined and reduce the amount of emulsion concentrates required for our production Coolant / Soluble Aqueous Parts Washer Waste Oily Water BVL Wash Tank Tennant Floor Cleaner Plastic Recycled Plastic waste is removed from site by a local waste handling company. The waste is pelletized and reused with the plastic manufacturing industry reducing the amount of waste sent through to landfill. A slight increase from 214 is a reflection of an increase in production. [t] Plastic Recycled [Total Parts Produced] ,, 12,, 9,, 2 6,, 1 3,, Plastic Total Parts Produced

12 Verifier s Declaration The undersigned, Dipl.-Phys. R. Mirz, EMAS Environmental Verifier, registration number DE-V-26, accredited or authorized for the area designated by NACE code 29 confirms that his inspection of the location at Waleswood Road, Wales Bar, S26 5PN Sheffield as indicated in the updated environmental statement (Environmental Protection and Occupational Safety Report) of) LuK (UK) Ltd, registration number D complies with all requirements stipulated by (EU) Directive No /29 by the European Parliament and Council dated November 25, 29 on the voluntary participation of organizations in a joint system for environmental management and eco-audits (EMAS). The signature at the end of this statement confirms that >> the inspection and validation have been completed in full agreement with the requirements stipulated in (EU) Directive 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 (Environmental Protection and Occupational Safety Report) for the location at Waleswood Road, Wales Bar, S26 5PN Sheffield as part of LuK (UK) Ltd represent a reliable, credible and true picture of all activities at this location within the area indicated in the environmental statement. This statement cannot be equated to EMAS registration. EMAS registration can be completed by an authorized agency in accordance with (EU) Directive No /29. This statement must not be used as an independent basis for informing the public. Dipl.-Phys. R. Mirz LuK (UK) Ltd, 2/7/215 Questions about environmental Protection at the location: Sheffield David Wright Waleswood Road Sheffield, South Yorkshire, S26 5PN, David.Wright@schaeffler.com England: From other countries: Questions about environmental protection by Schaeffler: Norbert Hörauf Industriestraße Herzogenaurach Norbert.Hoerauf@Schaeffler.com Germany: From other countries: 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 im Dezember 215 This publication or parts there of may not be reproduced without our permission. The next consolidated (entire) Environmental Statement will be submitted for validation in Juli 216 at the latest. In the years between, an annual update of the Environmental Statement will be compiled for validation by the environmental verifier.