Le nuove frontiere dell'energy management

Transcription

1 Le nuove frontiere dell'energy management Esperienze di successo di energy saving e management June 2010 Ing. Paolo Segreto, ECOMAU Sales & MKTG Property of Comau S.p.A. - Duplication prohibited

2 Agenda COMAU CORPORATE PROFILE ENERGY EFFICIENCY FOR COMAU GROUP EN 16001: COMAU APPROACH ECOMAU: THE ENERGY EFFICIENCY INDUSTRIAL ENABLER May 2010 Property of Comau S.p.A. - Duplication prohibited

3 COMAU CORPORATE PROFILE May 2010 Property of Comau S.p.A. - Duplication prohibited

4 Our Mission COMAU IS A GLOBAL AND INNOVATIVE PROVIDER OF SUSTAINABLE AUTOMATION AND SERVICE SOLUTIONS MARKET IS THE AUTOMOTIVE SECTOR AND OTHER INDUSTRIES REQUIRING PROCESS AUTOMATION SOLUTIONS BASED UPON COMAU TECHNOLOGICAL KNOW-HOW AND EXPERIENCE May 2010 Property of Comau S.p.A. - Duplication prohibited 4

5 Our Distinctive Strategy HIGH COMPETENCE TO COVER A WIDE RANGE OF KEY TECHNOLOGIES FULL INTEGRATED CAPABILITY IN PRODUCT, PROCESS AND SERVICE SOLUTIONS SOLUTION ORIENTED GLOBAL A NETWORK OF 23 OPERATIVE CENTERS LOCATED IN 14 COUNTRIES, LED BY GLOBAL PROCESSES 60% RESOURCES IN BRIC COUNTRIES HIGH DENSITY AUTOMATION CELLS TO TUNE AND OPTIMIZE INVESTMENTS ENERGY SAVING PRODUCTS AND SERVICES SOLUTIONS INNOVATIVE GLOBAL PROJECT MANAGEMENT SYSTEM BASED ON PMI STANDARDS, CUSTOMIZED ON LOCAL MARKET NEEDS AND CULTURES LEAN PRODUCTION APPROACH May 2010 Property of Comau S.p.A. - Duplication prohibited 5

6 Core competencies BODY WELDING FINAL ASSEMBLY METAL CUTTING ASSEMBLY & TEST LASER WELDING ARC WELDING SEALING DRILLING & RIVETING May 2010 Property of Comau S.p.A. - Duplication prohibited 6

7 Multi technology competencies BODY SHOP TECHNOLOGIES POWERTRAIN MACHINING & ASSEMBLY FINAL ASSEMBLY SYSTEMS ROBOTICS & AUTOMATION MAINTENANCE SERVICES May 2010 Property of Comau S.p.A. - Duplication prohibited 7

8 References AUTOMOTIVE May 2010 AEROSPACE HEAVY INDUSTRY PUBLIC TRANSPORTATION ENERGY DEFENSE RECREATIONAL Property of Comau S.p.A. - Duplication prohibited 8

9 Facts AUTOMOTIVE 1 OUT OF EVERY 3 VEHICLES IN THE WORLD, OVER 20 MILLION ANNUALLY, ARE MANUFACTURED WITH COMAU TECHNOLOGY AEROSPACE AUTOMATIC DRILLING AND RIVETING FOR JOINT STRIKE FIGHTER WITH NORTHROP GRUMMAN ENERGY SOLAR CELLS MANUFACTURING PROCESS WITH BOEING SERVICE HIGHEST MARKET SHARE IN INDUSTRIAL MAINTENANCE SERVICES IN BRAZIL, FROM AUTOMOTIVE TO DIVERSIFIED GENERAL INDUSTRY 9

10 Figures 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 10

11 Comau Group Network LUTON TRAPPES CASTRES BOBLINGEN TYCHY DETROIT MOSCOW TEPOTZOTLAN TURIN SHANGHAI ORADEA BELO HORIZONTE PUNE CORDOBA 11

12 ENERGY EFFICIENCY FOR COMAU GROUP

13 ECOmau Strategic Initiative 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 and ISO 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 and ISO 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.

14 Fiat Group/Comau Sustainability Main Targets EN All Fiat Group Plants goal Certification of Energy Management System EN Certification Environment Management System ISO goal ISO All Fiat Group Plants Waste management improvement Biodiversity conservation Mapping and specific action plan for the plants in sensitive areas Subsequent action plan goal goal Mapping of plants in order to consider criticality for external noise and water availability Energy and environment Key Perfomarmance Indicator compliance C 2 Reduction plan for energy consumption and CO2 production

15 Energy Group: Methodologies & Targets PROJECTS MANAGING F-MATRIX COLLECTION (per company) EXTENSION & KNOW-HOW DIFFUSION ENERGY VECTOR AGGREGATION EEM Pillar -LCC - Capitolati PROJECT ANALYSIS & TEST AREAS BEST PRACTISES 15

16 Main objectives: Sustainability Action Plan Fiat Group & Comau commitment Energy reduction target: encouraging the use of environmentally friendly materials - 15 % Vs KPI Timeframe: 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 New products range (PWT, BWA & ROB) designed for sustainable manufacturing Provides its sustainability process know-how to achieve the energy efficiency targets

17 EN & The Supply Chain Requirements 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. RFQ Requirements Trends Quality 9001 Environment Health And Safety Mandatory Mandatory / Suggested Declared, if available Now Future? EnMS EN16001 Energy Saving Recommendations Mandatory RFQ Requirements

18 EN 16001: COMAU APPROACH

19 Why EN 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 Product Quality Environment Energy Management certifications EN 16001:2009 European standard reference Released: July 2009 ISO Energy Management Worldwide standard Proposed to replace the EN being fully compliant with it Estimated release: May 2011 ISO 9001 EN ISO OHSAS Workers Safety

20 Energy Management Facts & Figures before EN16001 Plants located in Grugliasco (TO) Energy Management supplied by:

21 Grugliasco Energy Manager Site & Facility Manager Castres Energy Manager Site & Facility Manager Oradea Energy Manager Site & Facility Manager Detroit Energy Manager Site & Facility Manager Betim Energy Manager Site & Facility Manager Cordoba Worldwide coordination Energy Manager Site & Facility Manager Tepotzolan Energy Manager Site & Facility Manager Energy Manager Site & Facility Manager Energy Manager Site & Facility Manager Pune Shanghai EN Worldwide Team Antonio Pastore Comau Sector Energy Manager

22 New Roles 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.

23 Comau Italy (Grugliasco) EN Certification Steps Calendar Week Program Dev. & Planning Training Procedures & KPI s Dev. External Audit Step 1 & 2 Corrective Actions Final Audit Certificate emission = Completed = Planned

24 Comau WW EN and ISO Overall Certification Plan Calendar EN Achieved! On Going Planned ISO OK Planned

25 Energy Efficiency Action Plan Some 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

26 Energy Management Compressed Air 4 Compressors ATLAS COPCO mod. GA 90, GA 110 Average Energy Consumption: 8% Actions taken: leak analysis, management optimization & max pressure reduction

27 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:

28 RES Application PV roof installation (on evaluation phase) Stab. 3 latitudine di Nord longitudine Est Tipo di installazione: integrato ( su shed) Superficie disponibile: m2 Orientamento: SUD-OVEST (Azimut: 13 ) Stab.4 latitudine di Nord longitudine Est Tipo di installazione: integrato (su shed) Superficie disponibile: m2 Orientamento: SUD-OVEST (Azimut 13 ) Dati tecnici: - Pn modulo FV: 220 Wp - Num. Moduli: Superficie coperta: m² - Potenza Totale : kwp - Stima Producibilità annua: MWh

29 THE ENERGY EFFICIENCY INDUSTRIAL ENABLER

30 Green Automation Consulting COMAU DEVOTES SIGNIFICANT RESOURCES TO TURN THE GREEN-COMMITMENT AND ENVIRONMENTAL RESPONSIBILITY INTO 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 CONSULTANCY ON EXHISTING MANUFACTURING SYSTEMS 30

31 GreenFit Methodology Assessment Intervention definition and site implementation Part working [W]; 369; Emergency stop [W]; 258; 2% 4% Dry cicle [W]; 4059; 39% Stand by [W]; 5648; 55% Monitored period: Power 17% Air 22% Coolant 9/29% Standby mode : Power 77% Air 48% Coolant 100% Monitoring and Results validation

32 ECOmau positioning Eco-innovation as driver of sustainable manufacturing Phase 1: ( ) Phase 2:

33 Green Roadmap for Comau Group Consulting & Service New Products Range EnMS EN RES Advanced Assembly Solution

34 R&D Projects

35 Sustainability R&D: CAPRI- Kinetic Energy Recovery System Title: CAPRI Control System for High Performance Industrial Robots BU involved: Funding Agency: Funding Scheme: Main Objectives: Expected Results: ROB MSE Ministry of Economical Development National Law 46/82 FIT Project N. A01/1903/1-3/X09 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 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. Timetable: Partners: (36 months) COMAU, CRF, STMicroelectronics

36 Sustainability R&D: Plant Cockpit Title: PlantCockpit BU involved: Funding Agency: Funding Scheme: Main Objectives: Production logistics and sustainability cockpit PWT France European Commission - FP NMP-ICT-FoF Large-scale Integrating Project (CP-IP) Study of a central environment for monitoring and control of all intra-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. Expected Results: Timetable: 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 (36 months) SAP (DE), COMAU (IT), Acciona (ES), BMW (DE), Doehler (NL), EPFL (CH), Fatronik (ES), Iconics (CR), Intel (ER), TUT (FI), UniDresden (DE)

37 Sustainability R&D: AluSiSec Title: AluSiSec - Aluminium Usinage à Sec/MQL BU involved: Funding Agency: Funding Scheme: Main Objectives: Expected Results: Industrial Research on Dry cutting/mql for Aluminum PWT (France) French Ministry of Industry National Call on Advanced Eco-efficient Technologies 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 The main results will be the following: advanced MQL and Dry-cutting technologies for eco-efficient machining Timetable: Partners: prototype module for eco-efficient machining (30 months) RENAULT (FR), COMAU (FR), LSMP (FR)

38 Contacts Paolo Segreto, Sales & MKTG Comau SpA Via Rivalta 49, Grugliasco (TO) - Italy Mob.: