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  • MS_Umwelterkl/Titel+RS/E 18.04.2003 9:32 Uhr Seite 1

    It is our duty to consider theconsequences of our actionsat all times.

    Mahatma Gandhi

    Environmental Repor t 2002 Update / Location Graz

    update

  • update 02This abridged version of the environmental report contains updateson the most important subjects. For details of long-term projects,please refer to the Environmental Report 2001.

    g/ /

  • contents1 MAGNA STEYR Fahrzeugtechnik AG & Co KG: The Company ................ 51.1 History of MAGNA STEYR............................................................................................ 51.2 Magna Group and Organizational Structure .................................................................. 61.3 Changes in 2001 ........................................................................................................61.4 Changes in 2002 ........................................................................................................71.5 Innovations ................................................................................................................71.6 New Members of the Environmental Team ....................................................................7

    3 Facts & Figures ................................................................................ 93.1 Input/Output Balance ................................................................................................ 93.2 Airborne Emissions .................................................................................................. 103.3 Wastewater ............................................................................................................ 113.4 Recycling and Waste Disposal ....................................................................................123.4.1 Waste Volumes .................................................................................................. 12/133.4.2 Waste Treatment...................................................................................................... 143.5 Energy and Resource Consumption ...................................................................... 15/163.6 Local Phenomena .................................................................................................... 173.6.1 Noise ......................................................................................................................173.6.2 Traffic and Transport ................................................................................................17

    4 Environmental Services Provided in 2002 ...................................... 18/19

    7 Environmental Auditors & Certificate .................................................. 23 The complete Section 7 is to be found in the MAGNA STEYR Environmental Report 2001

    1

    34

    7

    9 Contacts .......................................................................................... 23 9

    2 Environmental Management System (EMS) .......................................... 8The complete Section 2 is to be found in the MAGNA STEYR Environmental Report 2001

    5 Our Environmental Impact .................................................................. 20The complete Section 5 is to be found in the MAGNA STEYR Environmental Report 2001

    2

    56 2003 Environmental Program ...................................................... 21/22 6

    8 Abbreviations .................................................................................... 23The complete Section 8 is to be found in the MAGNA STEYR Environmental Report 2001 8

    g/ /

  • >> 4

    MAGNA STEYR Fahrzeugtechniks Graz-Thondorf plant is

    poised for a quantum leap into a completely new dimension of

    automotive production. The number of vehicles manufactured

    here will be increased from 90,000 at present to around

    200,000, i.e. more than doubled. New manufacturing facilities

    therefore had to be built or the old ones extended in 2002 and

    the entire infrastructure adapted to cater for the planned

    expansion. Naturally such significant changes were not made

    without taking all the environmentally relevant aspects into

    consideration. For example,

    A closed circuit was installed in the paint shop at the former

    EUROSTAR plant that was integrated in MAGNA STEYR

    Fahrzeugtechniks Graz-Thondorf plant in summer 2002, which

    enabled the process wastewater to be reduced by two thirds

    Substantial energy savings have been achieved by changing

    the compressed air facility over from high to low pressure

    A special recycling group was set up in our complete vehicle

    engineering department to ensure that every aspect of a

    vehicles subsequent recyclability is taken into consideration

    in the early stages of development

    These and many other measures detailed in the Environmental

    Report document that the following principle applies and is

    strictly observed at MAGNA STEYR Fahrzeugtechnik: We are

    dedicated to taking environmental protection into consideration

    in all our activities! To show the rapid development at our site,

    the present abridged Environmental Report contains data from

    both 2001 and 2002.

    The Board

    The MAGNA STEYR Fahrzeugtechnik AG & Co KG Board(from left): Harald J. Wester, Herbert Demel, Hubert Hdl,Klaus Iffland, Wolfgang Sauerzapf and Wolf-Dietrich Schulz

    g/ /

  • 1928 1998

    Majority holdingin Steyr-Daimler-Puchacquired by Magna

    1899

    Austro Daimlermerged withPuchwerke

    PUCH foundedDaimler founded

    First companyfounded in Steyr by

    Josef and Franz Werndl

    1864 2001

    Steyr-Daimler-Puchrenamed

    MAGNA STEYR

    Magnafounded

    1957

    Steyr Daimlermerged with

    PUCH AG

    1935

    5

  • TESMAInternational Inc.

    DECOMAInternational Inc.

    INTIERAutomotive Inc.

    >> 6

    11..22Magna Group and Organizational Structure

    Embedded in the Magna Group, MAGNA STEYR is the result of Magna Internationals systematic response to global competition. Its in-depth expertise has put the company at the top of the traditional supplier pyramid andenables us to offer our customers a truly unique range of products and services focusing on quality, innovativesolutions and reliability.

    11..33

    Changes in 2001

    The complete relocation of the former Components Division, which manufactured various products for thechassis, transmission and driveline, marked the end ofsingle part production at the Graz-Thondorf plant. Thishad a profound effect on our environmental impact, asthe wastewater and scrap levels in our output balance

    were substantially reduced as a result. Furthermore, MAGNA STEYR Fahrzeugtechnik rentedtwo external stores (Kastner and Lenhardt buildings)where cabling is manufactured for Division G and production parts are also kept.

    MAGNAInternational Inc.

    TESMAInternational Inc.

    DECOMAInternational Inc.

    * Supports the product groups in their expansion efforton the North American market.

    Wholly owned subsidiariesListed companies

    INTIER Automotive Inc.

    COSMAInternational

    MAGNA MirrorSystems

    Advanced development Basic research Styling and design concepts Project management Development of components,

    systems and modules, as wellas complete vehicles

    System integration Calculation and simulation Prototype manufacturing Rig testing On-vehicle testing Homologation Vehicle safety Space technology

    Mercedes-Benz E-Class Mercedes-Benz G-Class Jeep Grand Cherokee Chrysler Voyager Saab 93 convertible

    (from 2003) BMW X3 (from 2004) Complete body-in-white Class A stampings Production planning Logistics planning

    All-wheel drive systems:- Transfer case- Front axle drive- Rear axle drive

    Mass balancing systems

    Axle modules Chassis parts

    MAGNA STEYR North America*

    Powertrain

    Engineering Vehicle Assembly Driveline Chassis Modules

    Fahrzeugtechnik

    MAGNA STEYR is divided into two businessunits and four related, complementary product groups.

    g/ /

  • 7
  • >> 8

    2Nature doesnt have

    to make an effort to be

    important. It already is.

    Robert Walser

    1122

    Every new activity, new process and new product is thus examined for its environmentalimpact and evaluated in light of our corporateenvironmental goals. 33

    We take all the necessary steps to reduce any unavoidable burden on the environment to an absolute minimum by usingthe economically viable industrial resources that are available.

    99We involve our suppliers and service providers in our effort to improve environmental protection, and ensure that the contractorsworking on the premises comply with the same environment standards as we do. 1100Our company executives are fully aware of their responsibilities and do not simply demand all employees to be eco-conscious in everything they do, but undertake to set a good example themselves in the area of environmental protection.

    44In addition, we draw up plans and procedures to prevent environmentally hazardous accidents as far as possible and inthe event of a mishap to keep the impact under control. In this area we work in close cooperation with the authorities.55

    77In our research & development work we endeavor to make all productsrecyclable and take this requirement into account during the product development process.88Our clients, the general public and relevant authorities are informed annually of the impact that our company has on the environment and of our environment-related services.

    66We are dedicated to training all our people at every level by running coursesin the areas of environmental protection,waste management and recycling. As aresult, they can meet both the legal andcustomer-related demands, and becomemore involved in implementing thesystem.

    We at MAGNA STEYR are committed to complying with the applicable environmental legislation and regulations, and continuously improving environmental protection within the company. The Board therefore checks that the environmentalgoals are being met at regular intervals. Furthermore, we undertake to assess and monitor the environmental impact of ouroperations. Not only does this include wastewater, noise and airborne emissions, but also the levels and types of energysources, chemicals and supplies used, and waste disposal.

    To ensure that our conservation efforts in the company are successful, we per form regular environmental audits. This enables us to check the effectiveness of our environmental policy and pollution control measures, and ascertain whether all the steps taken comply with our environmental policy. Should any discrepancies emerge, corrective action is taken according to set procedures.

    The complete Section 2 is to be found in the MAGNA STEYR Environmental Report 2001

    EnvironmentalManagementsystem

    (ems)

    g/ /

  • 3facts & figures

    If we reduce Nature to

    what we understand,

    we will not be capable

    of survival.

    Hans-Peter Drr

    Raw materials:

    Metals: 38,114 t

    Finished material: 167,787,077 units

    Fabrics, leather and other

    trim materials: 58,622 m2

    Manufacturing supplies:

    Epoxy resin paint: 1,159 tEngine and other oils: 460 tFuel: 2,305 tOther coating materials: 557 tPhosphatizing agents and bonderizer: 20 tCleaning agents: 96 tAdhesives, SHR laminates: 93 t Wax, sealing materials: 2,590 tAcids: 8 tInert gas: 39,044 Nm3

    Oxygen: 56,001 Nm3

    Acetylene gas: 66 Nm3

    Media consumption:

    Electricity: 66,904 MWhNatural gas: 6,095,363 Nm3

    Compressed air: 35,041,003 m3

    Water: 294,947 m3

    Heat: 83,677 MWh

    Products

    Emissions

    Waste-water

    Waste

    INPUT OUTPUT

    MAGNA STEYRFahrzeugtechnik AG & Co KG

    Products:

    Jeep Grand Cherokee: 30,376 unitsChrysler Voyager 14,729 unitsMercedes-Benz G-Class: 9,072 unitsMercedes-Benz E-Class: 25,813 unitsMercedes-Benz M-Class: 12,279 units

    Airborne emissions:

    Solvent emissions: 153,897 kg LMOdor emissions: 767,967 MGECO

    2: 11,928,625 kg

    CO: 14,478 kgNO

    x: 9,428 kg

    Dust: 7,479 kgVOC: 132,208 kg

    Water output:

    Discharge to sewer: 233,441 m3

    Burst pipes, leakage: 5,000 m3

    Evaporation: 37,783 m3

    Watering: 1,600 m3

    Test track: 17,003 m3

    WC water disposal: 120 m3

    Waste disposal:

    Paper: 11,935,042 kgScrap: 2,281,470 kgDomestic-like industrial waste: 702,160 kgHazardous waste: 1,352,035 kgWood: 2,132,220 kgOrganic waste: 156,061 kgPlastic: 473,888 kgGlass: 55,370 kgBuilding rubble: 131,020 kgMiscellaneous: 251,507 kg

    33..11

    2002 Input/Output Balance

    9

  • Total solvent emissions

    Permit as per ruling for 160,000 carswithout small parts manufacturing

    Solvent emissions

    128,184 639,656

    272,100

    153,897

    272,100

    767,967

    1,256,0001,256,000

    kg [solvent/year] Odor [MGE/year]

    2001 2002 2001 2002

    The airborne emissions have not been affected by alterations to the facilities, except as a result of thechanges in the numbers of vehicles produced. As in2000, the figures for the year 2001 have been calculated because extensive measurements are

    only carried out at three-yearly intervals. Some of thefigures for 2002 are measured, but others extrapolatedsince the comprehensive measurement program wasnot completed by the end of 2002.

    The graph below shows the overall situation at the location.

    33..22

    Airborne Emissions

    Total 1999Total 2000Total 2001Total 2002

    Substances

    Airborne emissions

    100,000,000

    10,000,000

    1,000,000

    100,000

    10,000

    1,000

    100

    10

    1 Dust VOC CO CO

    2NO

    XSolvent

    5,738 108,893 13,583 13,147,039 9,121 161,2806,165 116,903 14,532 13,202,171 9,794 173,2146,159 104,404 11,950 10,875,321 7,415 128,1847,479 132,208 14,478 11,928,625 9,428 153,897

    [kg]

    >> 10

    g/ /

  • 19981999200020012002

    Substances

    Savings in chemicals per body

    8.0

    7.0

    6.0

    5.0

    4.0

    3.0

    2.0

    1.0

    0.0

    Liquid Liquid Powder calcium Liquid iron (II) hydrochloric acid caustic soda hydroxide chlorid (FeCI

    2)

    (HCI 33%) (NaOH 50%) (Ca(OH)2)

    total total

    Volu

    me

    [kg]

    33..33Wastewater

    Chemical consumption:

    3Having completely relocated the former ComponentsDivision, a major cause of wastewater at the plant hasbeen eliminated. The monitoring procedures introducedhave however been retained. In addition to the data

    from external tests, daily samples and analyses ensurethat the limits are observed. The most important parameters are to be found in the diagram below.

    Chemical use continued to be reduced by constantlyoptimizing wastewater treatment. The plant

    management is committed to maintaining this levelover the next few years.

    Wastewater volume: limit: 64.214m3/aCOD: limit: 27,400 kg/aZn load: limit: 109.5 kg/aPb load: limit: 43.8 kg/aNi load: limit: 32.85 kg/aCr load: limit: 8.14 kg/a

    Wastewater from the in-house treatment plant

    100,000

    10,000

    1,000

    100

    10

    1

    10.000

    1.000

    0.100

    0.010

    0.001

    0.0001999 2000 2001 2002

    29,297 28,211 21,478 23,09710,976 11,600 9,585 4,160

    1.7 1.6 2.8 3.00.145 0.257 0.298 0.00037.1 5.8 4.3 1.6

    0.119 0.203 0.038 0.0114

    11

  • Cardboard/paper 11,935,042

    Metal 2,281,470

    Wood 2,132,220

    Plastic 473,888

    Glass 55,370

    TOTAL 16,877,990

    Domestic-like industrial waste 702,160

    Other non-hazardous waste 251,507

    Building rubble 131,020

    TOTAL 1,084,687

    1,352,035

    156,061

    19,470,773

    Waste category Waste type Volume in kg (2002)

    33..44..11

    Waste Volumes

    33..44Recycling and Waste Disposal

    Recyclable materials

    Landfill waste

    Hazardous waste

    Biodegradable waste

    Total waste

    Biodegradable waste 1%

    Building rubble 1%

    Othernon-hazardous waste 2%

    Plastic 2%

    Scrap 14%

    Wood 12%

    Paper 61%

    Domestic-like industrial waste 2%

    Hazardouswaste 5%

    Waste output in % (2002)

    >> 12

    g/ /

  • 13
  • >> 14

    1. Recycling: used materials are recycled.

    2. Thermal treatment: waste fractions are incinerated and the residue then disposed of in a landfill (slag).

    3. Chemical/physical treatment: waste fractions are turned into new products using physical and/or chemical processes.

    4. Landfill: waste fractions go straight to the landfill.

    33..44..22

    Waste Treatment

    The following forms of waste treatment are used at MAGNA STEYR Fahrzeugtechnik:

    Waste treatment

    Chemical/physical treatment 3%

    Landfill 5%

    Recycling 88%

    Thermal treatment 4%

    g/ /

  • 33..55Energy and Resource Consumption

    Total electricity consumption [kWh]Electricity consumption per body [kWh]

    Year (bodies)

    Electricity consumption

    80,000,000

    70,000,000

    60,000,000

    50,000,000

    40,000,000

    30,000,000

    20,000,000

    10,000,000

    0

    1,800.00

    1,600.00

    1,400.00

    1,200.00

    1,000.00

    800.00

    600.00

    400.00

    200.00

    0.001998 1999 2000 2001 2002

    (38,283) (72,768) (85,865) (73,385) (92,269)61,327,800 73,198,400 71,237,200 59,367,488 66,904,2001,601.96 1,005.91 829.64 808.99 725.10

    [kW

    h/bo

    dy]

    [kW

    h]

    Year (bodies)

    Natural gas and compressed air consumption

    00

    00

    00

    00

    00

    00

    00

    0040,000,000

    35,000,000

    30,000,000

    25,000,000

    20,000,000

    15,000,000

    10,000,000

    5,000,000

    0

    700

    600

    500

    400

    300

    200

    100

    01998 1999 2000 2001 2002

    (38,283) (72,768) (85,865) (73,385) (92,269)5,110,033 6,717,956 6,746,127 5,557,139 6,095,36322,310,170 27,802,260 36,725,864 34,513,530 35,041,003

    133 92 79 75.73 66.06583 382 428 470.31 379.77

    [m3 /

    bod

    y]

    [m3]

    Total natural gas consumption [m3]Total compressed air consumption [m3]Natural gas per body [m3]Compressed air per body [m3]

    15

  • Total water consumption [m3]Water consumption per body [m3]

    Water consumption

    0

    0

    0

    0

    0

    0

    0

    0

    0

    1

    2

    3

    4

    5

    6

    7

    8

    9400,000

    350,000

    300,000

    250,000

    200,000

    150,000

    100,000

    50,000

    0

    9.00

    8.00

    7.00

    6.00

    5.00

    4.00

    3.00

    2.00

    1.00

    0.001998 1999 2000 2001 2002

    (38,283) (72,768) (85,865) (73,385) (92,269)309,452 310,423 329,546 260,233 294,947

    8.08 4.27 3.84 3.55 3.20

    [m3]

    per

    body

    [m3]

    Year (bodies)

    >> 16 Year (bodies)

    Consumption of other gases

    70,000

    60,000

    50,000

    40,000

    30,000

    20,000

    10,000

    0

    1.40

    1.20

    1.00

    0.80

    0.60

    0.40

    0.20

    0

    1998 1999 2000 2001 2002(38,283) (72,768) (85,865) (73,385) (92,269)26,200 13,100 32,800 28,400 6,60044,179 43,472 26,096 22,591 56,00145,980 54,858 60,577 52,441 39,0440.68 0.18 0.38 0.39 0.071.15 0.60 0.30 0.31 0.611.20 0.75 0.71 0.71 0.42

    [m3]

    per

    body

    Consumption trends for other gases:

    [m3]

    Acetylene (*10 -2) [m3]Total oxygen [m3]Total inert gas [m3]Acetylene (*10 -2) per body [m3]Oxygen per body [m3]Inert gas per body [m3]

    Total heat consumption [MWh]Heat consumption per body [MWh]

    Year (bodies)

    Heat consumption

    0

    0

    1

    1

    2

    286,000

    84,000

    82,000

    80,000

    78,000

    76,000

    74,000

    72,000

    70,000

    68,000

    66,000

    2.50

    2.00

    1.50

    1.00

    0.50

    0.001998 1999 2000 2001 2002

    (38,283) (72,768) (85,865) (73,385) (92,269)84,626 82,827 80,710 80,457 83,6772.21 1.14 0.94 1 0.91

    Leve

    l [M

    Wh]

    [MW

    h]

    Heat consumption trends:

    Water consumption trends:

    g/ /

  • 317
  • Goal Measure

    Environmental Services in 2002

    Respon-sible

    Imple-mentation

    CompletionDate

    Economizing on gloves and cleaningcloths by holding a workshop in theJeep BIW Division

    Economizing on abrasive disks by holding aworkshop in the Jeep BIW Division and by evaluating suppliers

    Renovating the railroad siding andsystematically replacing the wooden ties with longer life and less polluting concreteones (Rail Investment 2002)

    Standardizing the batteries used in corporatevehicles; installing a battery charging station,providing information on handling andmaintaining batteries from experts

    Selling such parts to the DaimlerChrysler usedparts center (for subsequent re-use)

    Roller burnishing instead of milling (no materialabrasion). Trials are currently being carried outon a tester and a concept for implementationin BIW will then be developed

    Optimizing supply processes

    Continuous process optimization

    Draining the transmission

    Renovating the manholes & pump shafts in the tanks in Building 1

    Reduction in residual waste by around5% in Division J

    Increase the service life of railroad ties

    Prolong the life of forklift batteries byaround 20% in Division G

    Reduction in waste volumes from rejects by about 8%

    Reduction in cap consumption on electrode holders by about 50%

    Increase in the share of re-usablepackaging (quantity not yetassessable)

    Reduction in hydrocarbon emissionsfrom complete vehicle projects

    Prevention of oil leaks when transporting transmissions

    Preventive maintenance

    JR

    JR

    AZ

    GPM

    GPM

    JRI

    AZT

    QWL

    AZV

    JMI

    OK

    OK

    OK

    OK

    OK

    OK

    OK1

    OK

    notpossible2

    still underway

    Jan. 02

    Feb. 02

    Jan. 02

    Feb. 02

    Dec. 02

    June 02

    Aug. 02

    ongoing

    Jan. 02

    Aug. 02

    Reduction in emissions (soil)

    Reduction in waste volume

    Reduction in emissions (air)

    environmentalservices provided in 2002

    There is something

    wonderful about

    every one of Natures

    creatures.

    1 Constantly increased2 Cannot be carried out because of some material and plant requirements

    Aristotle

    4

    >> 18

    g/ /

  • partlyimplemented3

    OK

    OK4

    OK

    OK

    OK

    OK

    OK

    OK

    OK

    OK

    OK

    OK

    OK

    OK

    AZ

    AZT

    AZL

    TAE

    TAE

    E, B, J, Q

    JPM

    JMI

    QWL

    J

    E

    E

    E

    QWL

    B, Q, TU

    Goal Measure

    Environmental Services in 2002

    Respon-sible

    Imple-mentation

    CompletionDate

    Cutting road transport

    Giving greater consideration to containerdimensions and increasing capacity utilizationon truck routes

    Changing over from rigid to folding containers

    Changing the compressed air supply from highto low pressure (removing the high-pressurecompressor; procuring a low-pressurecompressor; converting the high-pressuremachines)

    Replacing compressed air with blower air in the washing station in Building 2

    Involving employees in implementing the EU used vehicle directive taking banned substances into consideration by planning andusing conforming materials and systems only

    Installing a recirculated air system forpedestal mounting

    Improving working conditions for weldingby installing a welding smoke extractor(Assembly Maintenance Building 1;not a permanent welding workstation)

    Updating the contingency plan to improve procedures for accidents with chemicals

    Extending basic training for new recruits inDivision J (approx. 350 employees annually) to cover environmental issues

    Training courses, seminars and regular talkswith the waste manager

    In-house training and seminar program for productdesign taking recycling into consideration

    Increasing awareness among employees bywalking round the departments noting ideasand suggestions for improvements

    Targeted personnel training in all divisions

    Drawing up an extended environmentaltarget profile for outside companiesand suppliers

    Increase in rail shipments for new projects by about 100%

    More effective truck capacity utilizationby about 15%

    Improved freight space utilizationby reducing the space for emptiesby a third

    Energy savings of around200 MWh/year in compressedair production

    Energy savings of around114.4 MWh/year

    Avoidance of banned substances

    Reduction in exposure to pollution for employees

    Risk minimization for accidents involving chemicals

    Improvement in new employees knowledge of the environmental management system

    Sensitization of employees to wastemanagement

    Comprehension for meeting futurerecycling requirements

    Improvement in existing employeesknowledge of the environmental management system

    Increase in environmental awarenesswhen handling hazardous substancesand chemicals

    Improvement in the situation regardingoutside companies

    Jan. 02

    Jan. 02

    2002(ongoing

    changeover)

    Dec. 02

    Dec. 02

    Feb. 02

    Jan. 02

    May 02

    Jan. 02

    March 02

    ongoing

    ongoing

    ongoing

    ongoing

    Feb. 02

    Reduction in emissions (transport)

    Improvement in working conditions

    Reduction in resource consumption (compressed air)

    Reduction in indirect waste volume

    Compliance with the environmental and safety regulations atMAGNA STEYR Fahrzeugtechnik by outside companies and suppliers

    Improvement in environmental awareness among employees

    19

  • >> 20

    5

    The complete Section 5 is to be found in the

    MAGNA STEYR Environmental Report 2001

    ourenvironmental impact

    It is not the

    flowers and trees,

    but just the garden

    that belongs to us.Chinese saying

    hen examining environmentalimpact, we differentiate betweendirect and indirect effects.

    The direct ecological aspects areobviously easier to evaluate, and areassessed and compared at MAGNA STEYRFahrzeugtechnik using the environmentalscarcity method (environmental impactpoints model). It involves gauging theenvironmental impact of a product,process or company by calculatingthe eco-factors, which are a measureof the environmental relevance of onegram of a substance and are multiplied bythe actual amount used. This method iseasy to use and can be adapted anddeveloped as required.

    In addition, the environmental impactpoints for all the ecological aspects canbe added and therefore compared.

    The method also enables national,regional and local factors to be includedin the assessment, and the environmentalimpact on the various media to becompared direct.

    Indirect environmental impact may bedirectly related to the companysactivities, but only becomes apparent after some time or at a distance.It cannot therefore be completelycontrolled, thus representing a muchgreater challenge. Only measuresthat extend beyond the premisesthemselves, such as external audits,environmental regulations or contractprovisions enable the indirectenvironmental impact to be kept incheck to any great extent.

    W

    g/ /

  • GoalNo. MeasureCompletion

    date

    Responsiblefor

    completion

    Funds(EUR)

    Savings(EUR)

    Checking the necessity to SOP

    Successively replacing old PCs,printers and monitors withleased ones

    Replacing and separating rinsingfor fillers, primer and clearcoats (to achieve a higher solidcontent)

    Developing additional aluminumcompetence

    Giving HC emission greaterconsideration when selectingmaterials

    Delivering in 1,000 Liter TankW 210 now: 4-5 l oil left in drumper drum change;(14 drums a week)

    Purchasing oil-free pulsescrewdrivers: maintenance-freeand low-noise

    Modernizing the in-houseshuttles with new trucks andjumbo trailers to compensatefor rising transport volumes

    Using special reusablecontainers for rail transport,thus reducing truck transportand combating the rising roadtraffic volumes

    Using more folding containerseg replacing Euro skeleton boxeswith DB 2032 skeleton pallets

    2,500

    300,000 (in addition)

    2,000

    30,000

    30,000

    1.5m

    Reduction in packaging material(DEKOSTRIP-SAAB) (approx.100units/day = 200 Lfm)

    Reduction in electronic scrapby 30% compared with 2002

    Reduction in hazardous waste(paint sludge); paint shop H83

    Reduction in CO2 by increasinglyusing lightweight designs

    Reduction in HC emissions inthe vehicle

    Preventing oil leaks in aggregatepre-assembly at W 211

    Reduction in the repair intervalsand avoiding oil by replacing theold impact screwdrivers in G(c. 20)

    Avoiding additional pollutantemissions after increasingtransport frequency

    Reduction in the truck milk runsby changing over from truck torail transport

    Reduction in transport byimproving truck capacityutilization for empties

    1

    2

    3

    4

    5

    6

    7

    8

    9

    10

    March 03

    March 03

    March 03

    starting in2003

    ongoing

    May 03

    July 03

    March 03

    June 03

    dependingon project(constant

    changeover)

    LZV

    I

    OPA

    ED

    E

    GA

    GA

    LZT

    LZT

    Task for thevariouslogisticsplanningdivisions

    4,000/a

    500

    notassessable

    7,000/a (handling +remaining

    oil)

    7,000

    42,240/a

    170,000/a

    Environmental Program for 2003

    Reduction in waste volume

    Reduction in emissions (air)

    Reduction in emissions (soil)

    Reduction in emissions (transport)

    21

  • GoalNo. MeasureCompletion

    dateFunds(EUR)

    Savings(EUR)

    Developing and manufacturing acryo tank for hydrogen engines

    Outside light-dependent control,use of low-energy lighting

    IH personnel to detect andrepair the leaks when productionstopped

    By implementing status-orientedIH, i.e. the oils are analyzed tosee if they can continue to beused

    Installing a closed circuit waterplant for low-wastewater pre-treatment & CDP shop operationand replacing the wastewatertreatment plant

    Cr-free passivation inpre-treatment for lead-free CDP

    Disposing of resources nolonger required

    Sensitizing the designerswith regular training

    Staff training

    Ongoing process optimization

    Including the subject Theenvironment at MAGNA STEYRin apprentice training

    Changing over to electronic bil-ling and archiving. Introductionof e-invoicing together with TMM

    Obtaining product approval fromour partners (DaimlerChryslerand Saab)

    Drawing up a plant-wide stan-dard evaluation checklist forregular section inspection

    470,000investment

    1,500 in-house per-

    sonnelcosts

    2,200

    1,000,000

    300,000

    440,000(wastewater)

    in-house

    in-house

    in-house

    in-house

    in-housemeasure

    Development of modulesfor alternative drives

    Saving of at least 360,000kWh/a in lighting for Buildings2 and 3 (area 30,000 m2)

    Reduction in compressed airleaks in Buildings 1, 11 and 12totaling 5% of compressed airconsumption at production stop(200 l/sec without production)

    Reduction in transformer oilchanges by up to 90%corresponding to 39,000 kg(62 transformers each with700 kg oil capacity) for thescheduled change cycle

    Cut water consumption for everyreduction in wastewater volumein H83

    Reduction in use of criticalsubstances in ecological terms

    Reduction in volumes in the oilstores

    Products designed for recycling

    Increase in environmentalawareness when handlinghazardous substances andchemicals - in all divisions

    Assistance in implementation ofHC emission limits in completevehicle projects

    Teaching apprentices about envi-ronmentally relevant subjectsduring their training in a simpleand easily understandable form

    Minimizing the paper used whenchecking freight invoices

    Division Q to support MAGNASTEYR Fahrzeugtechniksenvironmental goals inintroducing eco-friendly systemsand with ongoing processoptimization - and observinglegal requirements on the partof QWL with its staff and tools.

    Identification of theenvironmental protectionstatus and its potential forimprovement

    11

    12

    13

    14

    15

    16

    17

    18

    19

    20

    21

    22

    23

    24

    Dec. 03

    Dec. 03

    Dec. 03

    March 03

    Feb. 03

    ongoing

    ongoing

    ongoing

    ongoing

    ongoing

    Aug. 03

    ongoing

    April 03

    VE

    TAE

    TRH

    TRE

    OPA

    O

    EGE

    EGE

    QWL

    QWL/ J

    TU

    LZF

    QWL

    TU

    17,000

    5,000(basis forcalculation25/m3)

    50,000(1.45/kg

    transformeroil)

    430,000

    80,000

    Environmental Program for 2003

    Reduction in resource consumption

    Improvement in working conditions

    Improvement in environmental awareness among employees

    Not classifiable

    >> 22

    Responsiblefor

    completion

    g/ /

  • environmentalauditors &certificate

    abbreviations

    contacts

    If you have any questions, please contact:

    MAGNA STEYR Fahrzeugtechnik AG & Co KGEnvironmental Management DepartmentLiebenauer Hauptstrasse 3178041 GrazAustria

    Roman PltnerEnvironmental ManagerPhone: +43/316/404-5629Fax: +43/316/404-2909E-Mail: [email protected]

    Erich EisnerDeputy Environmental ManagerPhone: +43/316/404-8498Fax: +43/316/404-2909E-Mail: [email protected]

    7+8

    9

    23

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    MAGNA STEYR Fahrzeugtechnik AG & Co KGLiebenauer Hauptstrasse 317, A-8041 GrazPhone: +43 (0)316 404-5629, Fax: +43 (0)316 404-2909E-Mail: [email protected]

    more valuemore car

    Environmental Report 2002 Updatepage update`02

    ContentsThe Board1 MAGNA STEYR Fahrzeugtechnik AG & Co KG: The Company1.1 History of MAGNA STEYR1.2 Magna Group and Organizational Structure1.3 Changes in 20011.4 Changes in 20021.5 Innovations1.6 New Members of the Environmental Team

    2 Environmental Management System (EMS)3 Facts & Figures3.1 Input/Output Balance3.2 Airborne Emissions3.3 Wastewater3.4 Recycling and Waste Disposal3.4.1 Waste Volumes3.4.2 Waste Treatment

    3.5 Energy and Resource Consumption3.6 Local Phenomena3.6.1 Noise3.6.2 Traffic and Transport

    4 Environmental Services Provided in 20025 Our Environmental Impact6 2003 Environmental Program7 Environmental Auditors & Certificate8 Abbreviations9 Contactsback page---------------------------------------------------