andreas harms, environmental protection, bmw...
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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
Tel. 012 522 3946
THANK YOU
ENVIRONMENTAL PROTECTION @ BMW SOUTH AFRICA