andreas harms, environmental protection, bmw...

CORPORATE SUSTAINABILITYTHROUGHOUT THE VEHICLE LIFECYCLE.

Andreas Harms, Environmental Protection, BMW

South Africa

March 2015

IMPLEMENTATION OF CORPORATE SUSTAINABILITYTHROUGHOUT THE VEHICLE LIFECYCLE.

ProductionRecycling

Research and

Development

Design for

Environment / Life

Cycle Engineering

Clean

Production

Sustainability

Standards

for Suppliers

End-of-Life

Recovery

Recycling

Concepts

Efficient Dynamics

Design for

Recycling

Product UtilizationBMW Group Page 2

BMW i8 AND i3.

Recycled materials

Savings

80 kg CO2e

Renewable raw materials

Savings

40 kg CO2e

25% OF THE WEIGHT OF THERMOPLASTICS USED ISREPLACED BY RECYCLED/RENEWABLE RAW MATERIALS.

BMW Group Page 4

Primary aluminium produced

with renewable energy

5 kg CO2e

Conventional

primary aluminium

10 kg CO2e

Secondary aluminium

2 kg CO2e

80% OF THE ALUMINIUM USED IS EITHER RECYCLED ORPRODUCED WITH RENEWABLE ENERGY

BMW Group Page 5

EXTERNAL RECOGNITION AS ONE OF THE MOST SUSTAINABLE AUTOMOBILE MANUFACTURERS.

- Dow Jones Sustainability Indexes: Sector leader 2014. The only automotive company continuously listed

since 1999.

- FTSE4Good: Listed in FTSE4Good Index.

- Carbon Disclosure Project: Industry leader 2011, 2012, 2013 and 2014. One of four companies acrosssectors listed on CPLI for five consecutive years.

- Oekom: Corporate Responsibility Rating oekom, Status Prime.

BMW Group Page 6

PLANT ROSSLYN.3 SERIES (F30).

PetrolDieselLHD RHDXDrive

ASSEMBLYPAINTBIWTOTAL VEHICLE

Page 7Plant Rosslyn

PLANT ROSSLYN.84% OF CARS DESTINED FOR EXPORT MARKETS.

USA 48.7%

Japan 13.7%

Australia /New Zealand

8.1%

Africa 0.1%

East Asia 4.4%Taiwan Hong Kong Singapore

China5.9%

South Africa 15.9%

India3.3%

2013

Figures

Page 8Plant Rosslyn

PLANT ROSSLYN. SUPPLY CHAIN.

Page 9Plant Rosslyn

NAFTA BCC

Suppliers

PLANT ROSSLYN.SUPPLIER NETWORK SOUTH AFRICA.

Page 10Plant Rosslyn

WASTE STRATEGY.PLANT ROSSLYNSTEPS TOWARDS „ZERO WASTE“

Andreas Harms, Environmental Protection, BMW

South Africa

March 2015

WASTE STRATEGY.“REDUCE RE-USE RECYCLE”.

Re-use

Recover

Dispose

Reduce

Recycle

– Avoid / minimize waste by planning and control

– Re-use waste, e.g. airbag cages and bentonite

– Sell a clean waste stream to a recycler

– Substitute a natural material with waste, e.g. paint sludge as fuel

– As a last resort, dispose of the waste to landfill.

Page 12Plant Rosslyn

WASTE MANAGEMENT.RECYCLING VOLUME.

Source: BMW Group Database ABIS

0

100

200

300

400

500

BM

W P

lant R

ossly

n

BM

W W

erk

Din

golfin

g

BM

W P

lant S

part

anburg

*

BB

A D

ado

ng*

BM

W P

lant T

ha

iland

BB

A T

iexi

BM

W P

lant O

xfo

rd

BM

W P

lan

t C

hen

na

i

BM

W W

erk

Lan

dsh

ut

BM

W W

erk

Berlin

Top10 Wood [t/month]

0

100

200

300

400

500

600

BM

W P

lan

t R

oss

lyn

BM

W P

lan

t Sp

arta

nb

urg

*

BM

W W

erk

Din

golf

ing

BB

A D

ado

ng*

BM

W P

lan

t Th

aila

nd

BB

A T

iexi

BM

W W

erk

Reg

ensb

urg

BM

W W

erk

Leip

zig

BM

W W

erk

Ber

lin

BM

W P

lan

t O

xfo

rd

Top10 Cardboard/Paper [t/month] Feb 2014

* Estimate

2012

2012

2013

2013

BM

W P

lan

t

Ro

ssly

n

BM

W P

lan

t

Ro

ssly

n

2014

2014

Page 13Plant Rosslyn

0

5

10

15

20

25

2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Abfall zur BeseitigungZIEL ohne regulatedWaste

Abfall zur BeseitigungIST (kg/Fzg)

WASTE MANAGEMENT PLANT ROSSLYN.DISPOSAL TO LANDFILL.

Plant Rosslyn

(incl. 2015 forecast)

[kg / unit]

Page 14

Waste to landfill target

(without regulated

waste)

Waste to landfill actual

(kg/unit)

Waste to landfill target

(with regulated waste)

Plant Rosslyn

WASTE MANAGEMENT PLANT ROSSLYN.CHALLENGES.

Page 15

2013

OPERATIONS

MANAGEMENT

CHALLENGE: LIMITED SPACE

AT THE WMC*

* WMC:

WASTE MANAGEMENT

CENTRE

Plant Rosslyn

WASTE MANAGEMENT PLANT ROSSLYNCHALLENGES

Page 16

CHALLENGE: RE-USE

(AIRBAG CAGES,

BENTONITE)

ACTION: SEGREGATE AT SOURCE

2013

2014

AIRBAG CAGES

Plant Rosslyn

WASTE MANAGEMENT PLANSTEP “0” WMC OPERATIONS

Waste Strategy, PA-74, March 2014 Page 17

ACTION DONE: REDUCE SYSTEM FILL

SET SHIFT TARGETS

JUST IN TIME

PLAN AND IMPLEMENT

RIGHT TOOLS

REVIEW AND IMPROVE

WASTE STREAMS.

SHIFT HANDOVER

WASTE MANAGEMENT PLANSTEP “1” SYMPTOMS

Page 18

HALVE THE GENERAL

WASTE AT THE COMPACTOR

ADD TWO WORKERS TO

WMC SORTING TABLE

-50%GENERAL WASTE COMPACTOR

2014 ACTION: RE-INTRODUCE A SORTING

TABLE OPERATION

Plant Rosslyn

WASTE MANAGEMENT PLANSTEP “2” ROOT CAUSE

Page 19

ACTION: REDUCE CONTAMINATION

OF PRODUCTION WASTE

FEEDBACK TO PRODUCTION

MANAGEMENT ON

PERFORMANCE

INCREASE QUANTITY AND

QUALITY OF WASTE BIN

INSPECTIONS IN

PRODUCTION

RECYCLING BANKS IN

PRODUCTION

5

GENERAL WASTE TO LANDFILL

Plant Rosslyn

WASTE MANAGEMENT PLANSTEP “3” SUSTAINABLE PLAN

1. Paint Waste 2. Production Waste Concept

3. Non Production Waste4. Waste Management

Capacity / Efficiencies / Tools

5. Legal Compliance

Filtration

Liquid prevention

Liquid removal

Centrifuge stability

Waste to Energy (cement kilns)

Segregation at source

Waste stream mapping

Just in time concept

Line side interfaces (handling/removal)

Exchange empties with fullies (parts)

Spatial Planning & Implementation

Corporate recycling

Culture, discipline

Integrated recycling stations

Awareness

(Early Learning Centre)

Adequate manpower

Sunken conveyor

Cardboard baler with hogger

Separation wood/cardboard

Baler for plastics

Compacting of styrofoam

Bin liners and stickersWaste License implications

Auditing

REDUCE RE-USE RECYCLE

Ro

ute

Tra

in C

on

cep

t

Page 20Plant Rosslyn

WASTE MANAGEMENT PLANSUMMARY

Page 21

STEP 0: OPERATIONS MANAGEMENT AT

WMC

STEP 1: FIGHT SYMPTOMS

STEP 2: ADDRESS ROOT CAUSE

STEP 3: SUSTAINABLE PLAN

Plant Rosslyn

WASTE MANAGEMENTSOLUTIONS

Page 22

SUNKEN CONVEYOR CARBOARD

BALER

PLASTICS BALING

Plant Rosslyn

WASTE MANAGEMENTSOLUTIONS

Page 23

PARTS DESTRUCTION

ENGINE CRUSHING

Plant Rosslyn

WASTE MANAGEMENTSOLUTIONS

Waste Strategy, PA-74, March 2015 Page 24

Environmental

Protection

Clean

Production

TYRES

RIMS

PUNCH

WASTE MANAGEMENTSOLUTIONS

Page 25

Environmental

Protection

Clean

Production

COMPACTED STYROFOAM

HEAT / PRESSURE COMPACTORPlant Rosslyn

WASTE MANAGEMENTSOLUTIONS

Waste Strategy, PA-74, March 2015 Page 26

Environmental

Protection

Clean

Production

WEIGHBRIDGE WHEELIE BIN TRAIN

MATERIAL HANDLING

WASTE MANAGEMENTCHALLENGES

Page 27

UNION

BUILDINGS CULTURE IN PUBLICUNDESIRABLE BEHAVIOUR

Plant Rosslyn

WASTE MANAGEMENTSOLUTIONS

Waste Strategy, PA-74, March 2015 Page 28

CANTEENS,

KITCHENSHYGIENIC DESIGN

WASTE MANAGEMENTSOLUTIONS

Waste Strategy, PA-74, March 2015 Page 29

PRODUCTION

OFFLINEFRAME FOR INTEGRATION

WASTE MANAGEMENTSOLUTIONS

Page 30

PUBLIC RECYCLING BANK

GLAS

SOUTSIDE MAIN

GATEROBUST DESIGN

Plant Rosslyn

SUSTAINABILITY REPORTENVIRONMENT

Andreas.Harms@bmw.co.za

Tel. 012 522 3946

THANK YOU

ENVIRONMENTAL PROTECTION @ BMW SOUTH AFRICA