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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


● 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


Core competencies

BODY WELDING

FINAL ASSEMBLY

SEALING

DRILLING & RIVETINGLASER WELDING

ARC WELDING

METAL CUTTING

ASSEMBLY & TEST


ROBOTICS & AUTOMATION

BODY SHOP TECHNOLOGIES

FINAL ASSEMBLY SYSTEMS

POWERTRAIN MACHINING & ASSEMBLY

Multi technology competencies

MAINTENANCE SERVICES


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


● 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


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


•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


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


PROJECTS MANAGING

F-MATRIXCOLLECTION (per company)

ENERGY VECTORAGGREGATION

PROJECT ANALYSIS &TEST AREAS

BESTPRACTISES

EXTENSION &KNOW-HOWDIFFUSION

EEM Pillar- LCC- Capitolati

Energy Group: Methodologies & Targets


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


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


EN 16001: COMAU APPROACH


•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


Plants located in Grugliasco (TO)

Energy Management supplied by:

Energy Management Facts & Figures before EN16001


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Antonio Pastore

Comau Sector Energy Manager

Antonio Pastore

Comau Sector Energy Manager

EN 16001 Worldwide Team


• 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


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


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


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


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


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 €


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)


THE ENERGY EFFICIENCY INDUSTRIAL ENABLER


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


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


Phase 1: (2008-2010)

Phase 2:

Eco-innovation as driver of sustainable manufacturing

ECOmau positioning


RES

“Advanced Assembly Solution”

New Products Range

EnMS EN 16001

Consulting & Service

Green Roadmap for Comau Group


R&D Projects


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:


Sustainability R&D: Plant Cockpit

PWT FranceBU involved:

European Commission - FP7-2010-NMP-ICT-FoFFunding Agency:

Large-scale Integrating Project (CP-IP)Funding Scheme:


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:


Sustainability R&D: AluSiSec

PWT (France)BU involved:

French Ministry of IndustryFunding Agency:

National Call on Advanced Eco-efficient TechnologiesFunding Scheme:


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:


•Paolo Segreto, Sales & MKTG

•Comau SpA

•Via Rivalta 49, 10095 Grugliasco (TO) - Italy

•Mob.: +39 335 6576715

•e-mail: [email protected]

Contacts

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