Gestione Energia: ISO 50001 ed energy management Milano, 10 ottobre 2012, Doria Grand Hotel - Fire
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Gestione Energia:
ISO 50001 ed energy management
Milano, 10 ottobre 2012, Doria Grand Hotel
AGENDA
• COMAU
• eCOMAU
• ISO 50001: Green Procurement
• R&D: European Projects
Property of Comau - Duplication prohibited October 2012 2
COMAU MISSION
COMAU IS A GLOBAL AND INNOVATIVE
PROVIDER OF SUSTAINABLE AUTOMATION
AND SERVICE SOLUTIONS
TARGET MARKET:
AUTOMOTIVE SECTOR
AND INDUSTRIES REQUIRING
PROCESS
AUTOMATION SOLUTIONS
BASED UPON COMAU
TECHNOLOGICAL KNOW-HOW
AND EXPERIENCE
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FIGURES
ONE TEAM
MORE THAN 35 YEARS OF EXPERIENCE
5 RESEARCH & DEVELOPMENT CENTERS
14 MANUFACTURING PLANTS
23 OPERATIVE CENTERS
13 COUNTRIES
102 PMI® CERTIFIED PROJECT MANAGERS
14,500 EMPLOYEES WORLDWIDE
11,000 EMPLOYEES IN EMERGING COUNTRIES
Property of Comau - Duplication prohibited October 2012 5
REFERENCES
AUTOMOTIVE AEROSPACE HEAVY INDUSTRY PUBLIC
TRANSPORTATION
ENERGY DEFENSE RECREATIONAL
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COMAU GROUP ORGANIZATION
CROSS FUNCTIONS BUSINESS UNITS
BODY WELDING
INDUSTRIAL OPERATIONS
POWERTRAIN SYSTEMS
ROBOTICS
PROJECT MANAGEMENT OFFICE
AEROSPACE
ENERGY MANAGEMENT TEAM
ADAPTIVE SOLUTIONS
QUALITY SERVICE
BRIC PRESENCE
WE WORK DIRECTLY WITH CUSTOMERS IN THEIR AREA, FOCUSING ON THEIR REQUIREMENTS
AND TAILORING ALL COMAU PRODUCTS, SOLUTIONS AND SERVICES TO THE SPECIFIC LOCAL NEEDS
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Services - Green Automation Consulting
COMAU DEVOTES SIGNIFICANT RESOURCES TO TURN
THE GREEN-COMMITMENT AND
ENVIRONMENTAL SUSTAINABILITY
INTO REAL ENERGY SAVING RESULTS,
DEVELOPING SHORT TERM PAYBACK
GREEN AUTOMATION SOLUTIONS
IN MATERIAL HANDLING, WELDING,
METAL CUTTING AND ASSEMBLY SYSTEMS
COMAU ALSO OFFERS GREEN-FIT® CONSULTANCY
ON EXISTING MANUFACTURING SYSTEMS
®
Property of Comau - Duplication prohibited October 2012
THE MARKET: “AN UNEXPLOITED OPPORTUNITY”
Improving energy efficiency is key to reducing greenhouse gases
Development of global potential for European energy consumption and
energy efficiency improvements1 savings potential by 20202
• Energy Efficiency is biggest lever for • EU has significant potential for energy
reducing global greenhouse gases savings, especially in buildings.
Source: 1 Eco-efficiency. Chapter 6 – Environmental performance of constructions
2 Communication from the European Commission: Action Plan for Energy: Realising the potential 2006 Efficiency (source Susi Partners)
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eCOMAU NETWORK
DETROIT SÃO PAULO TURIN BIELSKO BIALA SHANGHAI
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BUSINESS MODEL: ENERGY EFFICIENCY FOR MANUFACTURING
Consulting Service
IMPROVEMENT OF MANUFACTURING YOUR ENERGY MANAGEMENT
PROCESSES IN EE PERSPECTIVE IN GOOD HANDS
•Industrial Energy Managers • Industrial Energy Managers
•Product / Process experts focused on sustainable design, • Utilities management for all kind of industries
Green-FitTM, LCC Analysis
•Green manufacturing
•Green procurement
•Funding & Incentives
Green Products & Technologies
“PLUG & SAVE" ON PROPRIETARY SOLUTIONS NON PROPRIETARY SOLUTIONS
• Comau Robotics: robots equipped with C5G Control Unit • Buildings (heating, cooling, lightning monitoring
• Comau Powertrain: Smart Drive, Urane systems…)
• Comau Body Welding: Versaroll • Painting systems
• Trigeneration / Cogeneration
Property of Comau - Duplication prohibited October 2012 11CONSULTING FOR INDUSTRIAL PROCESSES
eCOMAU‘s five steps of energy efficiency consulting process
1 2 3 4 5
Analysis of data Proposal of energy Implementation &
(electricity, compressed efficiency actions monitoring of energy
air, water, …) efficiency solutions
Implementation of Simulation
measuring systems
Property of Comau - Duplication prohibited October 2012 12ENERGY CONSUMPTION MIX…
PER INDUSTRIAL SECTORS IN AUTOMOTIVE MANUFACTURING
(EU27)
AUTOMOTIVE SECTOR:
• Average Energy Consumption
Source: European Environment Agency - 2009 • Weight Vs Process
Property of Comau - Duplication prohibited October 2012 13eCOMAU FOR THE AUTOMOTIVE INDUSTRY
Property of Comau - Duplication prohibited October 2012 14EMISSIONS / WASTE FROM CAR MANUFACTURING
Body Parts
Raw Stamping/ Surface Air emissions
Machining Welding
material Molding Treatment
Solid waste
Waste water
Sealers & Oil waste
Painting Adhesives Oil mist
Scrap
Powertrain
Raw Machining
Casting
material
FINAL ASSEMBLY
Components
Raw Painting
Manufacturing
material
Property of Comau - Duplication prohibited October 2012 15GREEN-FITTM
RETROFIT activity focused on energy saving for all
manufacturing automated processes
BW Machining Robotics Painting
Property of Comau - Duplication prohibited October 2012 16CASE STUDIES - PROCESS ENERGY EFFICIENCY
PAINTING TRANSFER
CNC ROBOTICS
LINES LINES
ITALY ITALY & POLAND ITALY & POLAND ITALYMACHINING CENTERS
Process: Machining
Description: Installation of monitoring systems and Green-FitTM
Yearly energy saving equivalent 1.537.359 kWh (3 shifts)
Reduction of CO2 emissions: 999.283 Kg
ROI: < 2 years
NB: data refer to 92 COMAU 1GXL machining centers
Machining electrospindle with
axes driven by ball screws with
horizontal electrospindle
• single spindle
• twin spindle center
Property of Comau - Duplication prohibited October 2012 18ISO 50001: IL COINVOLGIMENTO DEI FORNITORI
Oggetto: politica energetica
Comau è impegnata nella gestione responsabile ed efficiente dell’energia di tutte le sue attività: sviluppo prodotto, progettazione,
approvvigionamento, realizzazione ed installazione dei propri sistemi di automazione industriale.
Consapevole dell’esigenza, a livello mondiale, di una maggiore sostenibilità ambientale, Comau intende perseguire il miglioramento continuo
della propria performance energetica e la conseguente riduzione delle emissioni di gas serra, in piena coerenza con i valori e le politiche di Fiat
Group.
Nell’ottica di garantire tale obiettivo, Comau è impegnata nell’implementazione e mantenimento di un Sistema di Gestione per l’Energia per
tutti i propri siti produttivi, in conformità allo standard internazionale ISO 50001:2011.
Il Sistema si basa sui seguenti principi:
•Sostenibilità ambientale
•Miglioramento continuo della prestazione energetica
•Identificazione ed utilizzo di indicatori di performance, che verifichino il raggiungimento dell’obiettivo
•Sensibilizzazione dei propri fornitori sui temi dell’efficienza energetica
•Rispetto degli obblighi legislativi
La responsabilità nella gestione energetica riguarda l’intera organizzazione, conformemente alla specifica mansione e competenza di ogni singolo
lavoratore.
A tal fine, l’organizzazione definisce e comunica la politica energetica, gli obiettivi di risparmio energetico, i comportamenti attesi ed i relativi
programmi di attuazione.
Comau mette a disposizione tutte le risorse necessarie ad attuare e controllare il sistema per il raggiungimento degli obiettivi stabiliti, nonché a
formare, sensibilizzare e render consapevoli i propri dipendenti.
Property of Comau - Duplication prohibited October 2012 19A.5.7 Procurement of energy services, products and equipment
A.5.7.1 Procurement of energy services and products
Procurement is an opportunity to improve energy performance through the use of more
efficient products and services. It is also an opportunity to work with the supply chain and
influence its energy behaviors.
The applicability of energy purchasing specifications may vary from market to market.
Energy purchasing specification elements could include energy quality, availability, cost structure,
environmental impact and renewable sources.
C5G : next generation Robot Control Unit
Property of Comau - Duplication prohibited October 2012 20Urane – SD: Energy Saving features
Micro filtered air automatically closed after 30 minutes production break
(new valve)
Hydraulic system motor automatically stopped during production break
Coolant pump inverter managed, variable speed for different tools
Motor automatically stopped when HP is not required (part change, tool
change, stop production, ..)
Exchanger fan switch-off when internal temperature is under 30 degrees
Axis automatic standby mode during part change and production break
Machine sleeping mode during stop production (power-off machine)
Property of Comau - Duplication prohibited October 2012HIGH PAYLOAD ROBOTS
Focus on Smart NJ4 “Hollow Wrist”: all the advantages of a revolutionary project
Integrated dressing from the base to the flange of the
robot
Parallelogram structure with no balancing mass
Perfect symmetry of the mechanical structure
Strong, agile and streamlined kinematic structure
Reduction in cycle-time
Low power consumption
Reduced footprint
Possibility of installation both on floor and ceiling
100% off-line programming
2 versions available: Standard and Shelf
Property of Comau - Duplication prohibited October 2012C5G Control Unit
C5G : next generation Robot Control Unit
High processing power
the C5G uses the latest generation of industrial PC’s APC820
with Core 2 Duo technology CPU which is capable to obtain
high performances with low energetic consumption
Modular system for drives unit and I/O
Modular system for drives up to 9 or 10 axis in the base cabinet
function of the power
Compact dimensions
800x500x1100 mm
Free and ergonomic space for application functions integration
Energy saving system
Lowest consumption in stand by. Low consumption during
operations
Cooling system proportional to the level of the Control Unit’s
operations
Energy network recover system with program of high dynamic
content
Property of Comau - Duplication prohibited October 2012RESEARCH & DEVELOPMENT
Launched in 2012, this project is funded by Torino Chamber of Commerce and managed by Piemonte
Agency.
It gathers 40 local companies working in: Energy, Waste, Water, Air and Noise reduction, Research &
Consulting, Renewable Energies, Photovoltaic and Thermal solar, Biobuilding, Biomasses,
Cogeneration, Wind, Geothermal.
Run in collaboration with the key players, small or medium companies, research centres and international
operators locally based.
Aims at:
Enhancing Environment & Energy companies’ technological competences
Promoting Piedmontese excellences in the enviornmental sector abroad
Enabling the sector’s growth, through individual or clustered actions
Finding new buyers or commercial partners abroad
Boosting business internationalization know-how.
For more information ambiente@centroestero.org
Property of Comau - Duplication prohibited October 2012 24EMC2-Factory
Title: EMC2-Factory
Eco Manufactured transportation means from Clean and
Competitive Factory
Funding Agency: European Commission - FP7-NMP-FoF-2011-1
Funding Scheme: Collaborative Projects - Large-scale Project
Main Objectives: Cleaner and more resource-efficient production in
manufacturing, aiming at increasing the overall
production systems efficiency:
• by decrease in the use of resources and energy
• in emissions and waste treatment
• recycling at the point of use
Expected Results: Sustainable manufacturing solutions in automotive,
aeronautical and railway production systems
Timetable: 2011 – 2014 (36 months)
Partners: CRF (I), COMAU (I), CNR-ITIA (IT), PoliMI (I), Siemens
CT (DE), TUD PTW (DE), TUB IWF (DE), Festo (DE),
Siemens TO (AU), TWI (UK), Senseor (FR), TNO (NL),
CECIMO (BE), Tecnalia (ES), Correa (ES), SPASA (ES),
AIUT (PL)
Property of Comau - Duplication prohibited October 2012 25PLANTCOCKPIT
Title: PlantCockpit
Production logistics and sustainability cockpit
Funding Agency: European Commission - FP7-2010-NMP-ICT-FoF
Funding Scheme: Large-scale Integrating Project (CP-IP)
Main Objectives: Development of a central environment for monitoring and control of
all intra-logistical processes in order to improve production
management, process efficiency and optimize resource utilization.
This will provide a holistic visibility of the plant, the current status,
bottlenecks, deviations and exceptions. This will be achieved by
defining standard interfaces and a reference model for integrating the
most prominent manufacturing processes.
Expected Results: The project will realize an integrated heterogeneous, multi-vendor
system landscapes including ERP, MES, SCADA, condition-based
maintenance, energy management, and other special-purpose
systems. The project will impact on lead time, purchasing processes,
better energy/resources management and overall efficiency of
processes.
Timetable: 2010 – 2013 (36 months)
Partners: SAP (D), COMAU (I), PoliMI (I), Acciona (E), BMW (D), Doehler
(NL), EPFL (CH), Fatronik (E), Iconics (CZ), Intel (IRL), TUT (FIN),
UniDresden (D)
Property of Comau - Duplication prohibited October 2012 26Ing. Paolo Segreto
eCOMAU Sales & Marketing
Energy Manager Comau Grugliasco
COMAU S.P.A.
VIA RIVALTA,30
10095 GRUGLIASCO (TO)
ITALY
TEL. +39 011 0049111
www.e.comau.com
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