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Property of Comau S.p.A. - Duplication prohibited
Esperienze di successo di energy saving e management
June 2010Ing. Paolo Segreto, ECOMAU Sales & MKTG
Le nuove frontieredell'energy management
May 2010 Property of Comau S.p.A. - Duplication prohibited
• COMAU CORPORATE PROFILE
• ENERGY EFFICIENCY FOR COMAU GROUP
• EN 16001: COMAU APPROACH
• ECOMAU: THE ENERGY EFFICIENCY INDUSTRIAL ENABLER
Agenda
May 2010 Property of Comau S.p.A. - Duplication prohibited
COMAU CORPORATE PROFILE
May 2010 Property of Comau S.p.A. - Duplication prohibited 4
Our Mission
44
COMAU IS A GLOBAL AND INNOVATIVE PROVIDER OF SUSTAINABLE AUTOMATION
AND SERVICE SOLUTIONS
BASED UPON COMAU TECHNOLOGICAL KNOW-HOW
AND EXPERIENCE
MARKET IS THE AUTOMOTIVE SECTOR AND OTHER
INDUSTRIES REQUIRING PROCESS
AUTOMATION SOLUTIONS
May 2010 Property of Comau S.p.A. - Duplication prohibited 5
● HIGH COMPETENCE TO COVER A WIDE RANGE OF KEY TECHNOLOGIES
● FULL INTEGRATED CAPABILITY IN PRODUCT, PROCESS AND SERVICE SOLUTIONS
Our Distinctive Strategy
● A NETWORK OF 23 OPERATIVE CENTERS LOCATED IN 14 COUNTRIES,LED BY GLOBAL PROCESSES
● 60% RESOURCES IN BRIC COUNTRIES
● GLOBAL PROJECT MANAGEMENTSYSTEM BASED ON PMI® STANDARDS, CUSTOMIZED ON LOCAL MARKET NEEDS AND CULTURES
● HIGH DENSITY AUTOMATIONCELLS TO TUNE AND OPTIMIZE INVESTMENTS
● ENERGY SAVING PRODUCTS AND SERVICES SOLUTIONS
● LEAN PRODUCTION APPROACH
SOLUTION ORIENTED
INNOVATIVE
GLOBAL
May 2010 Property of Comau S.p.A. - Duplication prohibited 6
Core competencies
BODY WELDING
FINAL ASSEMBLY
SEALING
DRILLING & RIVETINGLASER WELDING
ARC WELDING
METAL CUTTING
ASSEMBLY & TEST
May 2010 Property of Comau S.p.A. - Duplication prohibited 7
ROBOTICS & AUTOMATION
BODY SHOP TECHNOLOGIES
FINAL ASSEMBLY SYSTEMS
POWERTRAIN MACHINING & ASSEMBLY
Multi technology competencies
MAINTENANCE SERVICES
May 2010 Property of Comau S.p.A. - Duplication prohibited 8
AEROSPACE
References
AUTOMOTIVE
ENERGY
HEAVY INDUSTRY PUBLICTRANSPORTATION
RECREATIONALDEFENSE
June 2010 Property of Comau S.p.A. - Duplication prohibited 9
1 OUT OF EVERY 3 VEHICLES IN THE WORLD, OVER 20 MILLION ANNUALLY, ARE MANUFACTURED WITH COMAU TECHNOLOGY
Facts
AUTOMOTIVE
AEROSPACE
ENERGY
SERVICE
AUTOMATIC DRILLING AND RIVETING FOR JOINT STRIKE FIGHTER WITH NORTHROP GRUMMAN
SOLAR CELLS MANUFACTURING PROCESS WITH BOEING
HIGHEST MARKET SHARE IN INDUSTRIAL MAINTENANCE SERVICES IN BRAZIL, FROM AUTOMOTIVE TO DIVERSIFIED GENERAL INDUSTRY
June 2010 Property of Comau S.p.A. - Duplication prohibited 10
● ONE TEAM
● OVER 35 YEARS OF EXPERIENCE
● 3 RESEARCH & DEVELOPMENT CENTERS
● 14 MANUFACTURING PLANTS
● 23 DIFFERENT LOCATIONS
● 14 COUNTRIES
● 84 PMI® CERTIFIED PROJECT MANAGERS
● 11,700 EMPLOYEES WORLDWIDE
● 7,900 EMPLOYEES IN EMERGING COUNTRIES
Figures
June 2010 Property of Comau S.p.A. - Duplication prohibited 11
Comau Group Network
DETROIT
TEPOTZOTLAN
BELO HORIZONTE
CORDOBA
LUTON
TRAPPESCASTRES
ORADEA
MOSCOW
PUNE
SHANGHAI
TURIN
TYCHYBOBLINGEN
June 2010 Property of Comau S.p.A. - Duplication prohibited
ENERGY EFFICIENCY FOR COMAU GROUP
June 2010 Property of Comau S.p.A. - Duplication prohibited
•During the 2nd half of 2009 the ECOmau strategic initiative has been envisioned with the aim to follow some of the current world wide ECO sustainability trends.
•The initiative is oriented towards both internal (Comau) and external (Customers) aspects:
• Internal: to achieve EN 16001 and ISO 14001 Comau certification on a world wide footprint.
• External: to develop a new business opportunity in the ECO sustainability business area (Energy Management and Environmentally Friendly plants) .
• EN 16001 and ISO 14001 certificates are required by the current Fiat Group strategy and will increase Comau expertise and brand value in the ECO business.
•The new ECO business will allow Comau to exploit new business opportunities in Industrial Automation field. This will be achieved by leveraging current Comau expertise and its unique foot print of System Integrator the Automotive industry, and by exploiting its Service capabilities in Industrial Automation.
ECOmau Strategic Initiative
June 2010 Property of Comau S.p.A. - Duplication prohibited
Certification of EnergyManagement System
EN 16001
Energy and environmentKey PerfomarmanceIndicator compliance
Mapping of plants in orderto consider criticality for external noise and water availability
Reduction plan for energyconsumption and CO2 production
EN 16001All Fiat Group Plants
goal
C 2goal
goal
Subsequent action plan
Certification EnvironmentManagement System
ISO 14001
goal
ISO 14001All Fiat Group Plants
Waste management improvement
Biodiversity conservationMapping and specific
action plan for the plants in sensitive areas
Fiat Group/Comau Sustainability Main Targets
June 2010 Property of Comau S.p.A. - Duplication prohibited 15
PROJECTS MANAGING
F-MATRIXCOLLECTION (per company)
ENERGY VECTORAGGREGATION
PROJECT ANALYSIS &TEST AREAS
BESTPRACTISES
EXTENSION &KNOW-HOWDIFFUSION
EEM Pillar- LCC- Capitolati
Energy Group: Methodologies & Targets
June 2010 Property of Comau S.p.A. - Duplication prohibited
Main objectives:
• encouraging the use of environmentally friendly materials
• optimizing the use of resources in all activities, beginning with the design of products and processes
• developing and implementing processes which ensure increasing compatibility with the environment
• reducing waste and sorting used materials so that they can be recovered and recycled
Energy reduction target: - 15 % Vs KPI
Timeframe: 2010 - 2014
Provides its sustainability process know-how to achieve the energy efficiency targets
New products range (PWT, BWA & ROB) designed for sustainable manufacturing
Sustainability Action PlanFiat Group & Comau commitment
June 2010 Property of Comau S.p.A. - Duplication prohibited
Quality 9001
Environment 14001
Health And Safety 18001
•The certification process (i.e. ISO 9001, ISO 14001, OHSAS 18001) is a roadmap for the companies to achieve the best balance between 1st in class performance and the commitment in continuous improvement.
EnMS EN16001Energy Saving
Recommendations
Mandatory RFQ
Requirements
Now Future ?
RFQRequirements Trends
Mandatory
Mandatory / Suggested
Declared , if available
EN 16001 & The Supply Chain Requirements
June 2010 Property of Comau S.p.A. - Duplication prohibited
EN 16001: COMAU APPROACH
June 2010 Property of Comau S.p.A. - Duplication prohibited
•To implement a certified Energy Management System (EnMS)
•To develop a policy which take into account legal requirements and information about significant energy aspects
•To build and maintain systems and processes necessary to improve energy efficiency
•To reinforce the ISO 14001:2004 Environmental Management System (Comau already certified on most locations)
•To avoid “Green washing”
Energy Management certifications
•EN 16001:2009
• European standard reference
• Released: July 2009
• ISO 50001
• Worldwide standard
• Proposed to replace the EN 16001 being fully compliant with it
• Estimated release: May 2011
Energy Management
ISO 9001
ISO 14001
EN 16001OHSAS 18001
Environment
Workers Safety
Product Quality
Why EN 16001
June 2010 Property of Comau S.p.A. - Duplication prohibited
Plants located in Grugliasco (TO)
Energy Management supplied by:
Energy Management Facts & Figures before EN16001
June 2010 Property of Comau S.p.A. - Duplication prohibited
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Antonio Pastore
Comau Sector Energy Manager
Antonio Pastore
Comau Sector Energy Manager
EN 16001 Worldwide Team
June 2010 Property of Comau S.p.A. - Duplication prohibited
• Energy Manager (EM):
• He is responsabile for the coordination of the Energy Management System, his goal is to make the energy utilization more effective and efficient and to increasing the utilization of renewable energy resources (RES).
• He defines the investments level related to energy efficiency improvement to be analyzed and approved by the Top Management.
• He develops the Action Plan related to the agreed objectives and targets.
• He monitors activities and defines the required corrective actions.
• Site & Facility Management:
• He provides an operating support to EM to achieve the objectives and targets of the EnMS
• He operatively manages the proper operation of the equipment for the energy generation of the site and is responsible for the maintenance
• He collects and stores consumption data according to what is required by the EnMS
• He is responsible to apply the modifications defined in the Action Plan, according to timing and budget constraints previously agreed.
New Roles
June 2010 Property of Comau S.p.A. - Duplication prohibited
Calendar Week 2009 09 10 11 12 01 02 03
= Planned= Completed
2009 2010
Program Dev. & Planning
Procedures & KPI s Dev.
External Audit Step 1 & 2
Final Audit
Training
Corrective Actions
Certificate emission
Comau Italy (Grugliasco) EN 16001 Certification Steps
June 2010 Property of Comau S.p.A. - Duplication prohibited
Calendar 2010 1 2 3 4 5 6 7 8 9 10 11 12
EN 16001Achieved!
ISO 14001OK
Planned
PlannedOn Going
http://sostenibilita.fiatgroup.com/en-US/commitment/Pages/Stakeholders.aspx
Comau WW EN 16001 and ISO 14001 Overall Certification Plan
June 2010 Property of Comau S.p.A. - Duplication prohibited
Energy Efficiency Action PlanSome examples & benefits
- Air Compressed: leak analysis & management optimization
- RES application:
- Solar Thermal System (to be implemented within 2010)
- PV roof installation (on evaluation phase)
- Lighting (evaluation of best available technologies):
- LED Lighting, High Efficiency Lamps, Automatic switch on/off system
June 2010 Property of Comau S.p.A. - Duplication prohibited
Average Energy Consumption: 8%
Energy Management Compressed Air
4 Compressors
ATLAS COPCO mod. GA 90, GA 110
Actions taken:
leak analysis, management optimization & max pressure reduction
June 2010 Property of Comau S.p.A. - Duplication prohibited
RES Application Solar Thermal System (to be implemented within 2010)
Dati Tecnici Stabilimento 3
- n° 1 Caldaie da esterno da 110 kWt- n° 2 bollitori da 2000 lt ciascuno- 60 m2 di pannelli solari
Dati Tecnici Stabilimento 4
- n° 2 Caldaie da esterno da 150 kWt totali- n° 3 bollitori da 2000 lt ciascuno- 90 m2 di pannelli solari
Yearly Saving:
30.000 €
June 2010 Property of Comau S.p.A. - Duplication prohibited
Stab. 3latitudine di 45.051° Nord longitudine 7.577° EstTipo di installazione: integrato ( su shed)Superficie disponibile: 7970.4 m2Orientamento: SUD-OVEST (Azimut: 13°)
Stab.4latitudine di 45.051° Nord longitudine 7.577 EstTipo di installazione: integrato (su shed)Superficie disponibile: 20935.2 m2Orientamento: SUD-OVEST (Azimut 13°)
Dati tecnici:- Pn modulo FV: 220 Wp- Num. Moduli: 10.236- Superficie coperta: 17.063 m²- Potenza Totale : 2.252 kWp- Stima Producibilità annua: 2.720 MWh
RES Application PV roof installation (on evaluation phase)
June 2010 Property of Comau S.p.A. - Duplication prohibited
THE ENERGY EFFICIENCY INDUSTRIAL ENABLER
June 2010 Property of Comau S.p.A. - Duplication prohibited 3030
Green Automation Consulting
COMAU DEVOTES SIGNIFICANT RESOURCES TO TURN THE GREEN-COMMITMENT AND
ENVIRONMENTAL RESPONSIBILITYINTO REAL ENERGY SAVING RESULTS
DEVELOPING SHORT-TIME PAY-BACK GREEN AUTOMATION SOLUTIONS
IN MATERIAL HANDLING, WELDING, METAL CUTTING AND ASSEMBLY SYSTEMS
COMAU ALSO OFFERS GREEN-FIT CONSULTANCYON EXHISTING MANUFACTURING SYSTEMS
June 2010 Property of Comau S.p.A. - Duplication prohibited
GreenFit – Methodology
Monitored period: Power – 17% Air – 22% Coolant – 9/29%
Standby mode : Power – 77% Air – 48% Coolant – 100%
Intervention definition and site implementation
Monitoring and Results validation
Dry cicle [W]; 4059;
39% Stand by [W]; 5648;
55%
Part working
[W]; 369; 4%
Emergency stop [W]; 258; 2%
Assessment
June 2010 Property of Comau S.p.A. - Duplication prohibited
Phase 1: (2008-2010)
Phase 2:
Eco-innovation as driver of sustainable manufacturing
ECOmau positioning
June 2010 Property of Comau S.p.A. - Duplication prohibited
RES
“Advanced Assembly Solution”
New Products Range
EnMS EN 16001
Consulting & Service
Green Roadmap for Comau Group
June 2010 Property of Comau S.p.A. - Duplication prohibited
R&D Projects
June 2010 Property of Comau S.p.A. - Duplication prohibited
Sustainability R&D: CAPRI- Kinetic Energy Recovery System
ROBBU involved:
MSE – Ministry of Economical Development Funding Agency:
National Law 46/82 FIT – Project N. A01/1903/1-3/X09Funding Scheme:
2008 - 2011 (36 months)Timetable:
COMAU, CRF, STMicroelectronicsPartners:
The main results will be the following:
• Distributed architecture based on central standard control system for different robot size.
• Power distribution through bus;
• Signal and control transmission through field bus.
• Robot cell architecture for a braking power recovery.
Expected Results:
The purpose of the project is to develop a new electronic architecture for distributed robot distributed based on a central standard control system, designed to overcome the technical problems and cost of current solutions
Main Objectives:
CAPRI
Control System for High Performance Industrial Robots
Title:
June 2010 Property of Comau S.p.A. - Duplication prohibited
Sustainability R&D: Plant Cockpit
PWT FranceBU involved:
European Commission - FP7-2010-NMP-ICT-FoFFunding Agency:
Large-scale Integrating Project (CP-IP)Funding Scheme:
2010 - 2012 (36 months)Timetable:
SAP (DE), COMAU (IT), Acciona (ES), BMW (DE), Doehler (NL), EPFL (CH), Fatronik (ES), Iconics (CR), Intel (ER), TUT (FI), UniDresden (DE)
Partners:
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:
• delays of internal to external supply; • optimized purchasing processes; • better energy/resources management• overall efficiency of processes
Expected Results:
Study of a central environment for monitoring and control of allintra-logistical processes. Production supervisors, foremen and line managers will have the required visibility to make well-informed decisions for optimizing plant processes. This includes the holistic visibility of the plant, the current status, deviations and exceptions, and bottlenecks.
Main Objectives:
PlantCockpit
Production logistics and sustainability cockpit
Title:
June 2010 Property of Comau S.p.A. - Duplication prohibited
Sustainability R&D: AluSiSec
PWT (France)BU involved:
French Ministry of IndustryFunding Agency:
National Call on Advanced Eco-efficient TechnologiesFunding Scheme:
2009 - 2011 (30 months)Timetable:
RENAULT (FR), COMAU (FR), LSMP (FR)Partners:
The main results will be the following:
• advanced MQL and Dry-cutting technologies for eco-efficient machining
• prototype module for eco-efficient machining
Expected Results:
The purpose of the project is the study of advanced technologies for powertrain Aluminum machining based on minimal quantity lubrication and dry-cutting. The projects aims at improving the environmental aspects of PWT manufacturing (pollution reduction, decrease of energy consumption) at affordable costs
Main Objectives:
AluSiSec - Aluminium Usinage à Sec/MQL
Industrial Research on Dry cutting/MQL for Aluminum
Title:
June 2010 Property of Comau S.p.A. - Duplication prohibited
•Paolo Segreto, Sales & MKTG
•Comau SpA
•Via Rivalta 49, 10095 Grugliasco (TO) - Italy
•Mob.: +39 335 6576715
•e-mail: [email protected]
Contacts