environmental declaration 2019 · iso 14001 and is validated in accordance with the european...
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Environmental Declaration 2019
April 2019
2
Dear Reader,
This Environmental Declaration provides a window into occupational safety and environmental protection at HEIDENHAIN. It is written for our business partners, customers, employees, and neighbors, as well as for public agencies.
As part of our sustainable and environmentally friendly approach to corporate management, we devote special attention to environmental protection in all of our operational activities. Environmental protection is even anchored in our mission statement.
HEIDENHAIN continually invests in sustainable growth through the further development of already existing technologies and through the implementation of new ones. We develop and manufacture technologically cutting-edge products using modern, safe, and environmentally friendly production methods. We also bear a special responsibility for the health and safety of our employees.
For the sake of continuous improvement in occupational safety and environmental protection, an occupational safety and environmental protection system is used. This system requires all employees to play an active role in ensuring occupational safety and environmental protection at HEIDENHAIN. Operational processes are continually reviewed and modified as needed.
Our occupational safety and environmental protection system has been certified since 1996 in accordance with the global standard ISO 14001 and is validated in accordance with the European Eco-Management and Audit Scheme (EMAS).
This Environmental Declaration documents the current state of affairs.
Karl LandingerEnvironmental Protection Officer
Anna EnzingerManaging Director, Finance and Internal Services
Traunreut, April 11, 2019
Foreword
3
Contents
Foreword ...................................................................................2
HEIDENHAIN .............................................................................4
Occupational safety and environmental protection policy ...6
Environmental effects ..............................................................8
■■ Energy ............................................................................8
■■ Water and soil ..............................................................10
■■ Recyclables and waste .................................................12
■■ Emissions .....................................................................14
■■ Material usage .............................................................16
■■ Occupational safety and fire protection .......................17
Environmental protection program for 2019 ........................18
Results from the 2018 environmental program ...................19
Statement by the environmental auditor .............................20
4
Product program
Length measurement ■ HEIDENHAIN linear encoders measure
positions along paths of traverse.
Angular measurement ■ HEIDENHAIN rotary and angle encoders
determine the measured values of rotational movements and measure angular velocity.
Controls for machine tools ■ TNC controls regulate and control
machine tools. HEIDENHAIN Klartext programming allows part programs to be created with shop-friendly convenience.
Setup and calibration ■ HEIDENHAIN touch probes measure
tools and workpieces directly on machine tools. HEIDENHAIN encoders for the inspection and acceptance testing of machine tools measure machine geometry and evaluate the resulting data.
Measured value acquisition and display ■ HEIDENHAIN digital readouts display
measured values that have been ascertained by position encoders. HEIDENHAIN interface electronics adapt the encoder signals to the interface of the subsequent electronics.
Measurement and control technology for demanding positioning tasks
DR. JOHANNES HEIDENHAIN GmbH develops and manufactures high-accuracy linear and angle encoders, length gauges, rotary encoders, digital readouts, and numerical controls. HEIDENHAIN supplies its products to manufacturers of machine tools and to producers of automated equipment and machines, particularly for semiconductor and electronics manufacturing.
HEIDENHAIN is represented in nearly all industrialized countries—primarily through wholly owned subsidiaries. Sales engineers and service technicians support the user on-site with advisory services and servicing. The production sites and sales agencies of the companies connected to HEIDENHAIN employ approximately 8,500 people worldwide. At present, approximately 4,100 employees are employed at the Traunreut location.
The high quality of HEIDENHAIN products necessitates special production facilities and measuring equipment. Masters and submasters for the manufacturing of scales are produced in a clean room with special measures taken for temperature stabilization and vibration isolation. HEIDENHAIN develops and builds most of the machines it needs for the production and measurement of linear and circular scales, including the necessary copying equipment.
The company’s strong expertise in the fields of linear and angular metrology is reflected in the numerous customized solutions developed for users. These solutions include measuring and inspection equipment developed and built for many of the world’s standards laboratories, as well as angle encoders used in a number of telescopes and satellite receiving antennas. Of course, all of this experience benefits the company’s serial products as well.
In 2018, our Traunreut location sold over 2 million devices. The overall output quantity (the total weight of all products sold, including packaging) was more than 4,900 metric tons in 2018.
HEIDENHAIN
2015 2016 2017 2018
440 590 710 690
Energy consumption in GWh
CO2 emissions in metric tons
Fresh water consumption in m3
10.4
29,000
9.3
26,000
7.8
21,000
11.1
30,000
5
Production methods
The exceptionally high standards for the accuracy and quality of HEIDENHAIN products necessitate special production facilities. The cutting-edge production methods employed are continually adapted to meet the current state of the art. The main production processes used are as follows:
■ Basic machining and processing of metal and glass
■ Production of precision optical graduations
■ Assembly of printed circuit boards
■ Final assembly of components and devices
Environmentally relevant processes
A small proportion of the production processes take place in facilities requiring approval in accordance with the German Federal Immission Control Act and the Water Resources Act:
■ Power and heat generation in the gas-powered combined heat and power plant with central furnace
■ Reintroduction of water from metalworking and glass processing
Further environmental legal requirements apply to systems that deal with water-polluting substances and to emissions containing highly volatile solvents:
■ Handling, storage, and transport of hazardous materials and waste
■ Galvanic and chemical surface processing of optical glass and steel carriers, with pH neutralization of the rinse water
■ Manual and automated surface cleaning of semi-finished and finished products in graduation production with volatile solvents
■ Operation of recooling plants as part of ventilation systems
Production facilities
The production facilities of DR. JOHANNES HEIDENHAIN GmbH in Traunreut consist of the main plant located in the center of town and the Hochreit facility located roughly one kilometer away at the edge of town. Both facilities are industrially zoned. The overall Traunreut location covers an area of 300,000 m2, of which approximately 80 % has been developed and roughly 20 % is in a nearly natural state.
The Hochreit facility primarily houses sections of the metalworking and glass processing production areas. The environmental effects described in the following pages refer to both production sites, although the predominant share of these effects arise at the main plant.
Environmental effects from the Hochreit facility
6
Occupational safety and environmental protection policy
Occupational safety and environmental protection policy
Occupational safety and environmental protection are important features of corporate policy at HEIDENHAIN. Guidelines for occupational safety and environmental protection have been defined and serve as the basis for all decisions relating to occupational safety and environmental protection management.
Our ten guidelines for occupational safety and environmental protection
1 HEIDENHAIN works to continuously improve occupational safety and environmental protection as it relates to the safety and health of its employees and to the company’s consumption of resources and energy.
2 HEIDENHAIN strives for a higher level of occupational safety and environmental protection than is required by law.
3 HEIDENHAIN endeavors to eliminate potential hazards to its employees and the environment at all times, beginning in the design phase of its products and production processes.
4 HEIDENHAIN is committed to keeping its safety systems and organizational methods at the current state of the art.
5 HEIDENHAIN inspects, monitors, and evaluates its corporate activities for their effect on the safety and health of employees and on the environment.
6 HEIDENHAIN ensures the implementation of occupational safety and environmental protection policy through its management system, both in technical and organizational terms.
7 HEIDENHAIN trains and informs its employees in order to promote awareness for safety and environmental matters both inside and outside the company.
8 HEIDENHAIN also informs and motivates its contractual partners to think and act in a safety- and eco-conscious manner.
9 HEIDENHAIN endeavors to ensure the seamless flow of information to public authorities as part of a cooperative working relationship.
10 HEIDENHAIN informs its customers and the public with regard to the safety and environmental aspects of our company and its products.
17
2015 2016 2017 2018
3735
2015 2016 2017 20182015 2016 2017 20182015 2016 2017 2018
Input
1717
2015 2016 2017 2018
22
Output
26
35
2416
36
25
Waterin dm³
Emissions (CO2)in kg
Wastein kg
Energyin kWh
Wastewaterin dm³
Input-Output-Balance per kg of product
1.09
0.750.64
0.890,72 0,780,79 0,73
7
Environmental protection management
HEIDENHAIN utilizes an environmental protection management system to translate its core corporate policy guidelines into practical courses of action.
In order to ensure the goal-oriented implementation of environmental protection management at HEIDENHAIN, the overall context of the company was determined based on the requirements of the interested parties. The resulting environmental factors serve as the basis for environmental protection goals and concrete measures for continuous improvement. In this regard, the applicable legal requirements represent a minimum criterion.
The environmental protection goals are defined and evaluated based on performance metrics. These metrics are defined during ascertainment of the environmental effects for environmentally relevant processes. Through the periodic review of the current metrics, the suitability, appropriateness, and effectiveness of the environmental protection management system is evaluated. The continuous improvement processes thereby lead to a reduction in environmental effects.
The environmental protection management system is monitored through internal occupational safety and environmental protection audits that are performed on a regular basis in the departments. Audit participants include specially trained auditors, the relevant heads of department, the company physician, and the works council. Random checks were conducted for compliance with all regulatory standards of ISO 14001 and the EMAS European audit scheme. Any discovered deviations were documented and resolved through corrective measures within the required amount of time.
An environmental protection officer appointed by the Managing Directors monitors the company’s compliance with its occupational safety and environmental protection policy. The environmental protection officer supervises the officers for emissions control, water protection, waste, and hazardous materials.
Ascertainment of environmental effects
The environmental effects are ascertained through examination of the environmentally relevant corporate processes. HEIDENHAIN analyzes these effects with regard to the following factors: auxiliary materials and supplies, waste, energy, emissions and water/soil. Energy and material consumption are measured for each of these factors, and the use of environmentally relevant systems is examined. The results are expressed as performance metrics. The corporate processes are evaluated for both normal operating procedure as well as for potentially occurring operational disturbances.
We are aware that the consumption of resources and the disposal of generated waste cause air and soil pollution; that harmful emissions contribute to air pollution, summer smog, and the greenhouse effect; that the consumption of energy and water accelerates the scarcity of resources; and that wastewater contaminants contribute significantly to soil and water pollution.
Input-output statement
The input-output statement represents the environmentally relevant flow of material and energy per kilogram of manufactured product. This approach allows us to compare environmental data over long periods of time and provides meaningful data even when production quantities fluctuate.
2015 2016 2017 2018
1717 17 16
in kWhPer kg of product
2015 2016 2017 2018
Overallin GWh
Thermal energy
Electric energy
73.5
18.6
54.9
79.0
22.7
56.3
73.6
18.7
54.9
77.8
20.8
57.0
8
Combined heat and power plant (CHP): low resource consumption for heat and power generation
The company’s combined heat and power plant runs on natural gas and is used to generate both heat and power based on the principle of cogeneration. The production of heat and power at the site of consumption allows for an excellent total utilization rate.
Coverage of energy requirements
The CHP generates approximately 9 % of the company’s total required energy needs. The remaining required power is sourced from an external, national energy provider with a renewal energy proportion of 53 %.
Coverage of heating requirements
The combined heat and power plant is used for both heat and power generation. The heat it produces is used for heating purposes and meets more than half of the company’s entire heating needs.
In addition, the company is connected to the Traunreut district heating system, which sources its heat from a biomass heating plant and a geothermal power plant. The biomass heating plant is powered by wood chips, waste wood, and natural gas. The geothermal power plant is fed with geothermal heat from hot thermal water. The share of renewable energy of the district heating system is approximately 82 %.
The remainder of the required heat energy is provided by a single central heating system and multiple decentral heating plants, most of which run on natural gas.
The percentage of energy from renewable sources is approximately 40 % of total consumption.
Based on the principle of cogeneration,
the combined heat and power plant
produces both electrical power for
manufacturing facilities as well as
thermal energy for the heating of
buildings.
Energy consumption
Environmental effects
Energy
9
Angle encoders feature accuracies down to the angular
second range and below. The special atmosphere
required for their production is ensured by complex,
state-of-the art ventilation systems.
The glass scales, which feature
accuracies in the micrometer
range, are manufactured in the
Mastering department. These precise
manufacturing processes place very
stringent demands on the quality
and reliability of the clean-room
technology.
Limiting energy needs
HEIDENHAIN strives to reduce energy consumption and to improve energy efficiency in new buildings and through the energy rehabilitation of existing buildings.
New buildings
For new buildings, the energy-efficient operation of the building is taken into consideration as early as the planning stage. In particular, the structural thermal insulation of the building envelope, as well as the energy efficiency of the building services technology for heating, ventilation, air conditioning, and lighting, must meet strict legal requirements for energy conservation in buildings.
Thanks to the use of environmentally friendly, state-of-the-art technologies, such as heat recovery for air-conditioning systems, a reduction in the environmental effects was achieved for various new production buildings.
Energy rehabilitation of existing buildings
For the improvement of energy efficiency in existing buildings, care is taken that buildings and building services systems undergo energy rehabilitation as needed, subject to economic considerations. The goal is to ensure the economical and therefore also the environmentally friendly operation of existing buildings.
Energy monitoring
An extensive energy monitoring system that transparently tracks the energy consumption of all buildings is currently under expansion. Through continuous monitoring of the consumption rates, negative trends are easier to analyze, and specific weaknesses can be identified. The energy monitoring system thereby contributes to the optimization of energy consumption.
37
26
2015 2016 2017 2018 2015 2016 2017 2018
35
22
35
24
36
25
Overallin m³
Evaporation from cooling towers /air humidifiers
Production wastewater
Sanitary sewage
Per kg of productin dm³
Freshwater consumptionAmount of wastewater
92,000
169,000
49,000
28,000
74,000
149,000
47,000
28,000
66,000
149,000
55,000
28,000
95,000
177,000
52,000
30,000
10
Environmental effects
Water and soil
Fresh water
Approximately 177,000 cubic meters of fresh water was consumed in 2018. Fresh water is sourced entirely from the public mains of the Traunreut waterworks.
Wastewater
Water types and quantities
Production water, sanitary water, and rainwater must all be dealt with. In 2018, approximately 125,000 cubic meters of production and sanitary wastewater were generated. The amount of sanitary sewage is calculated based on a yearly average consumption rate of approximately 8 cubic meters per employee.
The difference between freshwater consumption and wastewater production was due to evaporation from cooling towers and air humidifiers.
Pretreatment of wastewater
Before being discharged into the public sewage system, a portion of the produced wastewater is pretreated with the following equipment:
■ Grease interceptors
■ Ultra-filtration plant
■ Flow neutralization systems
The grease interceptor separates out grease and oil from the wastewater and rinse water produced by the company cafeteria. It is operated in proper accordance with the relevant legal requirements.
An ultra-filtration plant is used for treating wastewater from the mechanical production area, but this applies to only a tiny proportion of the overall wastewater. The plant performs the functions of heavy metal precipitation and oil separation. Due to the legal requirements of the German Water Resources Act, legal approval is necessary for ultrafiltration.
Two flow neutralization systems are used for wastewater from the graduations production area. These systems treat and monitor the pH value of the lightly contaminated rinse water arising from graduation production.
Reintroduction into the water cycle
Rainwater from new buildings is returned to natural circulation through the use of soakaway pits.
Wastewater is inspected on a regular
basis through the performance of
self-checks. So far, the measured
concentration levels have been
significantly below the legally
specified limits.
The increase in the specific water consumption in 2017 was due to significant increases in production and the expansion of certain facilities.
Freshwater consumption / wastewater
11
Inspection of pollutant concentration levels
Discharged concentration levels are checked annually by an externally accredited environmental laboratory. The wastewater load from the significant main points of accumulation is also monitored. For the most part, the results are well below the legally specified limits. Both the organic load and the load from nitrogen and phosphorous exhibit significantly smaller concentration levels than those found in household raw effluent. Other water-polluting substances, such as heavy metals, were likewise found at only very low concentrations. As a result, this water exhibits good biodegradability.
The requirements of the municipal drainage statute are therefore fulfilled.
Soil
In the interest of protecting soil and water from hazardous pollution, sites once suspected of contamination were formerly examined for hazardous substances in accordance with the specifications of the German Federal Soil Protection Act. The company grounds are now free of areas suspected of contamination.
The continuous-flow neutralization
system treats and monitors the rinse
water from graduation production
before it is introduced into the
sewerage system.
A key component of HEIDENHAIN encoders is their measuring
standard, which features a highly accurate graduation that plays a
crucial role in proper functioning and accuracy. The manufacturing
process for measuring standards generates wastewater in the form
of rinse water, which is neutralized before being released into the
public sewerage system.
2015 2016 2017 2018
2015 2016 2017 2018
382
122
72
286
218
293
934
2015 2016 2017 2018
519
107
78
263
190
260
855
292
111
63
263
149
254
818
106
250
16
291
153
267
790
Per kg of productin kg
Overallin metric tons
Waste and recyclables in metric tons
Glass
Commercial waste
Wood
Metal
Electronics
Paper
Other waste
Hazardous waste
0.780.790.723,061
3,5743,329
3,614
0.73
1,3791,188 1,301 1,307
12
Waste separation, waste treatment, and waste disposal
Waste separation: committed to recycling raw materials
The company generates the main following types of waste:
■ Metal from metalworking
■ Glass from graduation production
■ Wastepaper from offices
■ Cardboard from packaging
■ Electronic waste, especially from electronics production
■ Household-like commercial waste
■ Hazardous waste, particularly solvent-water mixtures and cooling lubricants
Waste treatment
All waste is separately collected and properly recycled or disposed of in accordance with the requirements of the German Waste Management and Product Recycling Act, including the hazardous substances regulations.
Waste disposal
Thanks to its consistent waste separation policy, HEIDENHAIN is able to recycle over 90 % of its waste. Most of the waste is disposed of by regional waste management companies. Hazardous waste is primarily disposed of by GSB Sonderabfall-Entsorgung Bayern.
Processing facilities reduce the size
of metal chips and remove moisture,
making them more economical to
recycle.
Due to a rise in renovation and remodeling work in existing buildings, 2017 saw an increase in the production of other types of waste.
As a result of significantly higher machine-tool usage times, cooling lubricant emulsions had to be disposed of more frequently, thereby causing an increase in the amount of hazardous waste in 2018.
Environmental effects
Recyclables and waste
Waste statistics
13
Many of the components in
HEIDENHAIN encoders are
manufactured in automated
production systems. The cooling
lubricants needed for metal cutting
are constantly monitored in order to
increase service life and reduce waste.
Rotary encoders convert rotational
motion into electrical signals using
the photoelectric scanning principle
for position ascertainment. Cooling
lubricants are used during the
production of the flange, which holds
the components of the rotary encoder.
Waste reduction methods in production facilities
Processing plant for metal chips
Two processing plants for metal chips are in use; one is located in the main plant in Traunreut and the other one in the Hochreit facility. The metal chips are first chopped up by a shredding unit, and residual emulsifiers are then removed in a centrifuge. The metal chips then have a moisture content of less than 1 % and can be recycled more effectively and economically. In order to avoid the transport of hazardous materials around the site, waste cooling lubricant is stored in central tanks located near the respective processing equipment.
Reduction of waste from coating processes
In the past, a protective coating was applied to the front panels of the contouring controls. Thanks to the increased use of stainless steel housings, the coating process has now largely been eliminated. The amount of waste arising from these processes has therefore been reduced.
Reduction in cooling-lubricant consumption
Through the growing use of centrifugal suction systems on encapsulated machine tools, the cooling lubricant that is carried along with the extracted emulsion and oil mists is separated and reintroduced into circulation within the given system.
Hazardous materials
The following hazardous materials arise from the company’s manufacturing processes:
■ A solvent-water mixture for the surface cleaning of semi-finished and finished products
■ Waste from coating processes, adhesive residue from assembly processes, and soiled cellulose cloths from cleaning activities
■ Diverse waste containing acids and bases from graduation production
Measures
Packaging
The hazardous materials are filled or packed into approved transport containers, and then declared and loaded in compliance with the currently valid regulations. Employees involved in the transport of these materials monitor the packing and loading processes with the help of a checklist. These employees receive job-specific training on a regular basis.
Training and monitoring
All of the employees involved in the transport of hazardous materials are trained and regularly instructed in accordance with their specific role. An external hazardous materials officer monitors compliance with the hazardous materials regulations.
2015 2016 2017 20182015 2016 2017 2018
750640
890
CO2 discharge per kg of productin grams
Carbon dioxide CO2
in metric tons
3,200
5,000
2,700
4,4001,090
2015 2016 2017 20182015 2016 2017 2018
Volatile organic compounds (VOC)in metric tons
VOC discharge per kg of productin grams
14.213.7 14.3
17.7
3.2 3.13.4 3.6
14
Environmentally relevant emissions
The company causes environmentally relevant atmospheric emissions primarily through the following processes:
■ Combustion processes in the company’s own combined heat and power plant
■ Gas and oil combustion for the central and decentral heating systems
■ Chemical surface treatment of components and devices, such as for coating and cleaning processes
Odor, dust, or noise emissions are produced only in low quantities.
The indirect environmental effects caused by the emissions from power procurement, district heating, passenger transport, and freight traffic are not currently taken into account.
Emissions from heat and power generation
The combustion processes used by the combined heat and power plant, and those of the gas-fed furnaces, primarily cause carbon dioxide emissions.
The amount of these emissions is calculated based on approximately 22 GWh of primary energy consumption from natural gas and heating oil.
Emissions from cleaning processes
The emission of volatile organic compounds (VOC) is due primarily to the cleaning of semi-finished and finished goods at various facilities and work areas. The primary cleaning agents used are alcohols and acetone. Most of the VOC emissions arise during production of the graduations, which is subject to special requirements in accordance with Article 31 of the German Federal Immission Control Act.
HEIDENHAIN precision graduations
feature line widths of 0.25 μm to
10 μm. The associated manufacturing
processes (e.g., DIADUR or
METALLUR) require special
investments in buildings, climate
control, and process technology.
The commissioning of various cleaning plants explains the increase in VOC emissions in recent years. Due to a
change in the measurement basis for VOC emissions, there are small differences in
the data compared with those of previous environmental declarations.
Emissions output
Environmental effects
Emissions
In 2016, carbon dioxide emissions were lower due to the replacement of the natural-gas combustion engines for the CHP, which
resulted in less operating time. After this overhaul, the operating time was significantly
increased in 2017, resulting in an increase in CO2 emissions but also leading to lower
energy consumption.
15
Solvents are chiefly used for cleaning
the surfaces of semi-finished and
finished products. Besides the
small amounts that enter the
wastewater during rinsing processes,
approximately half of the solvents are
disposed of as hazardous waste. The
remainder is released into the ambient
air.
Exposed linear encoders consist of a scale and a scanning head
that operate without mechanical contact. They are used on
machines and equipment with high accuracy requirements. The
manufacturing processes are continually optimized to reduce
the use of solvents.
Emissions monitoring
Due to the legal requirements of the German Federal Immission Control Act, pollutant emissions from the combined heat and power plant, as well as emissions from graduation production, must be monitored on a regular basis. To ensure compliance with the legally defined limits, recurring measurements are performed by an externally accredited environmental laboratory. For the most part, the results are well below the legally specified limits.
Emissions reduction measures
Emissions values are to be further reduced through building-related measures, particularly through heat recovery. The proportion of stainless steel front panels for contouring controls was increased, thereby reducing the amount of coating consumed.
2015 2016 2017 2018
671
120
718
252
672
121
726
280
Raw materialsin metric tons
Steel
Flat glass
Aluminum 1,230 1,036 1,348 1,451
2015 2016 2017 2018
Raw materials used per kg of productin kilograms
Steel
Flat glass
Aluminum 0.29
0.16
0.03
0.25
0.16
0.03
0.29
0.16
0.05
0.29
0.15
0.06
16
Conscientious use of material
Production at HEIDENHAIN is characterized by an unusually high level of vertical integration. HEIDENHAIN products are primarily made of steel, aluminum, flat glass, and electronic components. The production process encompasses metal machining, glass processing, graduation production, electronic production, and final assembly. The following raw materials, auxiliary materials, and supplies are used:
Steel and aluminum
Steel and aluminum are required primarily in the production of extrusions for linear encoders and of flanges for rotary and angle encoders.
Flat glass
Flat glass is required mainly as a carrier for precision graduations.
Solvents
Solvents are chiefly used for cleaning the surfaces of semi-finished and finished products.
The scale and scanning unit of sealed
linear encoders from HEIDENHAIN are
protected from chips, swarf, dirt, and
splash fluids by an aluminum housing.
Material usage
Environmental effects
Material usage
Cooling lubricants
Cooling lubricants are used for metalworking and glass processing in the production of graduations.
Acids and bases
Acids and bases are primarily used during the production of graduations. The surfaces of the encoder graduations are treated with galvanic and chemical processes. These substances are predominantly handled in closed systems, and the ambient air is monitored.
Chlorofluorocarbons
Chlorofluorocarbons are used as refrigerants in closed climatic cycles. Tiny amounts of these chemicals escape through leakage during the operation of air conditioning systems, and these losses are replaced accordingly. HEIDENHAIN endeavors to continue transitioning all of its heating, ventilation, and air-conditioning systems to environmentally friendly refrigerants and to reduce refrigerant losses.
Cardboard and wood
Cardboard and wood are used as highly recyclable packaging materials.
Material efficiency
For determining the material usage, we consider only three raw materials: aluminum, steel, and flat glass, which, along with electronic components, represent the primary mass-specific materials used in HEIDENHAIN products.
Material efficiency is the ratio of the amount of manufactured product to the amount of material used. Efficient material usage during production significantly contributes to the good stewardship of natural resources and to the economic efficiency of production processes. We continuously strive to quantify and analyze the key material flows of raw materials, auxiliary materials, and operating materials in order to identify viable savings potential.
The rise in absolute material usage is due to significant production increases.
17
Occupational safety
Evaluation of working conditions
For the purpose of ensuring the safety and health of all of our employees, the working conditions of all employees, including any associated exposure to hazards, are systematically evaluated on a regular basis in accordance with the German Occupational Safety and Health Act. All requirements for occupational safety, such as for plant and operational safety, are regularly examined through internal audits, and any necessary measures for improvement are taken.
Employee training and professional development
Because the majority of work accidents are caused by behavior-related mistakes, great emphasis is placed on the training of employees. Employees are regularly instructed by their supervisors regarding the dangers inherent in their duties and the measures required for effective prevention. Opportunities for further training on the topic of occupational safety are offered through an in-house training program and are attended based on the specific hazards that employees are exposed to.
Internal communication
The safety and environmental committee convenes regularly in order to promote internal communication between safety specialists, the company physician, the works council, and representatives of the various technical divisions. The committee members discuss occupational safety and environmental protection issues and jointly define required measures.
Fire protection
Fire protection for buildings
Fire protection for buildings is particularly taken into account during the planning of new buildings or when significant alterations are made to existing buildings. Building measures and fire protection systems such as fire alarm systems, fire extinguishing systems, and smoke and heat removal systems are defined in a separate fire protection certificate for the new property.
Technical fire protection
In order to ensure rapid and precise alerting in the event of a fire, a centralized fire alarm system is in place. When a fire alarm is triggered, an internal initial response group and the Plant Security team are notified by pager. Automatic fire extinguishing systems, wall hydrants, and a sufficient number of portable fire extinguishers are available within company facilities. For the general availability of extinguishing water, an adequate network of hydrants is present on the company grounds.
Fire protection at the organizational level
To improve corporate fire protection at the organizational level, employees receive basic and advanced training to become fire protection assistants. These employees are tasked with being able to use a fire extinguisher in the event of a fire and with supporting managerial staff, particularly the fire prevention officers, with fire prevention measures.
To ensure supply reliability for the company, the fire protection systems of suppliers are evaluated as part of the supplier audits.
HEIDENHAIN Plant Security monitors
safety on the company grounds
and coordinates measures for the
elimination of plant disturbances,
such as fire alarms.
Linear encoders from HEIDENHAIN are
used for linear position measurement,
such as on machine tools. They
ascertain the position directly on the
axis slide.
Occupational safety and fire protection
18
Environmental protection program for 2019
Goal Measures Date
Energy efficiency Increased energy efficiency for building services technology
The complete renovation of the ventilation systems of a production building is expected to make a key contribution to improved energy efficiency. Following the replacement of the air intake system and the refrigerating machines of the air conditioning system, the filter fan units of the clean-room equipment will be replaced with the best technology available. These measures are expected to save an additional 800 MWh of electrical energy per year.
2019
In another production building, the filter fan units of the clean-room technology are to be replaced with the best technology available. This is expected to save just under 500 MWh per year.
2019 to 2021
Due to the replacement of various refrigerating machines of the air-conditioning system with energy-optimized control technology, just under 100 MWh of electrical energy is expected to be saved per year. The improved control technology will adapt the cooling performance of the machine to the given cooling needs with as much precision as possible in order to ensure energy-efficient operation.
2019 to 2020
Environmental protection
Increased proportion of recyclable packaging material
For a sustainable packaging cycle, molded pulp is an environmentally friendly option because this fibrous material is based entirely on renewable raw materials that are completely recyclable. Packaging made of molded pulp has already been developed for one product family. In this case, a single molded pulp part forms the upper and lower packaging parts and can be used for all product variants. The necessary qualification tests were successfully completed, and the packaging can now be used for serial production.
2018 to 2019
Environmental protection goals
For the efficient implementation of the environmental policy defined for our company, environmental goals with specific environmental programs are developed and updated. This process is continually influenced by the results and experience gained from the annual environmental audit.
Environmental programs include measures in all areas of corporate environmental protection and are aimed at the reduction of our environmental effects as part of a continuous improvement process.
The release of the environmental program requires prior approval by the Managing Directors. Environmental programs must be compatible with the corporate environmental policy. In this context as well, the use of the technologically best processes and methods is meant to ensure the continuous improvement of environmental protection at HEIDENHAIN.
The environmental programs comply with all legal regulations but are expected to surpass them insofar as this is economically reasonable.
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Results from the 2018 environmental program
Goal Result
Energy efficiency
Increased energy efficiency for building services technology
The complete renovation of the ventilation systems of a production building is expected to make a key contribution to improved energy efficiency. Due to the state-of-the-art modernization of the air intake system, heat energy savings of over 800 MWh and electrical energy savings of 150 MWh per year were attained during the first step. In a further step, the refrigerating machines of the air-conditioning system were modernized, saving 300 MWh of electrical energy per year.
Energy efficiency was improved thanks to the replacement of a compressed air dryer with more advanced control technology, saving over 6 MWh of electrical energy per year.
Reduction in compressed air consumption in the metalworking production area
Despite being energy-intensive, compressed air is still indispensable for many applications, such as in production machines. The already begun optimization of the operating pressure and sealing air of the production machines in the metalworking production area is to be continued with a focused analysis of the compressed air consumption, particularly through the localization of compressed air leaks. This is expected to reveal further savings potential, and measures for improved energy efficiency are to be implemented.
Environmental protection
Increased proportion of recyclable packaging material
For a sustainable packaging cycle, molded pulp is an environmentally friendly option because this fibrous material is based entirely on renewable raw materials that are completely recyclable. Packaging made of molded pulp has already been developed for one product family. In this case, a single molded-pulp part forms the upper and lower packaging sections and can be used for all product variants. The required qualification tests were successfully completed, and the packaging can now be used for serial production.
Results from the environmental protection goals
The measures of action from the previous year’s environmental programs were largely implemented and led to improvements in the environmental impact of our products and production processes.
We have thereby achieved a high standard upon which we can continue to strive for environmentally friendly products and production processes in the future.
The results from the previous year’s environmental program highlight our efforts to sustain a continuous improvement process for the environmental effects of the Traunreut location.
The qualitative and quantitative improvements of the environmental effects are provided in the environmental data of the annual reports.
Within the context of the performance review and the effectiveness of the environmental goals, the quantified and scheduled environmental programs are also examined on an annual basis in consultation with the Managing Directors, and are redefined as needed.
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The signing party, Dipl.-Ing. Ulrich Wegner, EMAS environmental auditor from TÜV SÜD Umweltgutachter GmbH, with registration number DE-V-0045, accredited for group 26.5 (NACE code), hereby confirms that he has evaluated whether the company location stated in the updated Environmental Declaration of the organization
DR. JOHANNES HEIDENHAIN GmbH Dr.-Johannes-Heidenhain-Str. 5 83301 Traunreut, Germany,
with registration number D-155-00010, fulfills all of the requirements of Regulation (EC) No 1221/2009 of the European Parliament, and of the Council, of 25 November 2009, regarding the voluntary participation by organizations in an EC system for eco-management and auditing (EMAS) in conjunction with Commission Regulation (EU) 2017/1505.
With the signing of this Declaration, it is hereby confirmed that
■ the expert assessment and validation were conducted in accordance with the requirements of Regulation (EC) No 1221/2009 in conjunction with Commission Regulation (EU) 2017/1505,
■ that the result of the expert assessment and validation confirms that there is no evidence of any non-compliance with the applicable environmental regulations,
■ and that the data and information contained in the updated Environmental Declaration for the company location provide a reliable, plausible, and truthful portrayal of all activities at the location in the area stated within the Declaration.
Statement by the environmental auditor
DR. JOHANNES HEIDENHAIN GmbH has been validated in accordance with the European Eco-Management and Audit Scheme (EMAS) since August 21, 1996.
DR. JOHANNES HEIDENHAIN GmbH has been certified in accordance with the international environmental management standard DIN EN ISO 14001 since July 31, 1996, and with the quality management standard DIN EN ISO 9001 since 1993.
Munich, April 5, 2019
Ulrich Wegner Environmental Verifier
This Declaration is not equivalent to an EMAS registration. EMAS registration may be conducted only by a competent authority in accordance with Regulation (EC) No 1221/2009 in conjunction with Commission Regulation (EU) 2017/1505. This Declaration must not be used as the sole basis for informing the public.
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KLn 2046 · PDF · 04/2019