Environmental Statement Report Environmental
Transcrição
Environmental Statement Report Environmental
Environmental Statement Report Environmental Protection and Safety Location Calais 2014 2| Contents Contents Contents Environmental Protection Calais 2014 General Part Foreword A Message from the Partners Foreword by the CEO 4 4 6 Company Portrait 7 7 9 11 Our Divisions Success Factors Code of Conduct for Responsible Company Management Global Environmental Protection Schaeffler Environmental Protection and Occupational Safety Policy Environmental Communication 2011 EcoGlobe Awarded to Maria-Elisabeth Schaeffler 13 14 16 17 Environmentally Friendly Products 18 Social Responsibility 19 Location Part Location Presentation of the Calais Site The main modifications made to the site 20 20 25 Environmental Impacts Direct Environmental Impacts Indirect Environmental Impacts 29 29 35 Health and Safety 36 36 38 40 Risk Management Safety at work Social Aspects Environmental Indicators Key Indicators according to EMAS III Water Consumption Energy management Metal raw materials Waste Management Emissions Goals and Programs 41 42 44 46 49 50 51 Environmental programmes and targets Improvements not included in annual target planning 52 52 53 Validation and responsibility 54 |3 4 | Foreword A Message from the Partners Ladies and Gentlemen, with its INA, LuK and FAG brands, Schaeffler is a global technology leader in the automotive supplier industry for all renowned manufacturers as well as for customers from many other industrial sectors. A successful family-owned company, Schaeffler’s thinking and actions have a longterm orientation and thus focus on durable success taking all aspects of global activities into account. Schaeffler has set long-term ambitious goals with regard to innovative power, product quality, process quality and delivery reliability as well as a growth trend that secures large investments for successful innovations. At the same time, we have traditionally placed great emphasis on combining economic success with responsible actions for our customers as well as the environment and our employees. Georg F. W. Schaeffler, Maria-Elisabeth Schaeffler Worldwide compliance with the code of conduct for responsible and fair business and company management are part of our company principles and goals, as are environmental protection and occupational safety. Schaeffler incorporates environmental protection in all processes: from development to purchasing to manufacturing to disposal. Energy, water and materials are used sparingly and carefully. Waste is avoided by returning materials to the production cycle whenever possible or by recycling them. Foreword | 5 An essential tradition of our family-owned company is to place great importance on the responsibility we have for our employees, who guarantee the success of our company. Global compliance with high standards as well as recurring workstation analyses ensure the highest possible level of workplace safety for all employees. We are convinced that – against the background of our global responsibility – working, integrated environmental protection and occupational safety management represents an important contribution to our company’s sustainability. Our responsibility also includes providing innovative products to handle key problems of the future as well as developing and offering solutions that help reduce pollutant emissions in automobiles and increase the energy efficiency of vehicles and machines. This report on environmental protection and occupational safety documents the fact that Schaeffler successfully combines efficiency and environmental compatibility with the integration of social factors both inside and outside of the company. Maria-Elisabeth Schaeffler Georg F. W. Schaeffler 6 | Foreword Foreword by the CEO We believe that there is only one environment and that this environment is global ... Schaeffler unites its three great well-known brands INA, FAG and LuK under one roof. With more than 78,500 employees at over 180 locations worldwide we manufacture components and systems for the automotive industry and sixty other industrial sectors. Our commitment to active environmental protection and occupational safety has been firmly established in our company’s management principles from the very beginning. One of the first of these principles states, “Exemplary actions based on clearly defined ethical values determine our success.” It goes on to say: “We assume responsibility for our environment.“ Meeting this requirement means recognizing risks, analyzing and evaluating facts and making the right decisions for a particular situation. We established a group-wide environmental protection and occupational safety policy years ago to serve as guidelines for our actions. These guidelines are evaluated regularly and basic ideas are adjusted to match ever changing requirements. What is special about our environmental protection and occupational safety management system compared to many other companies is its worldwide implementation at the same high standard. We do not make a distinction between our plants in Germany, Europe, the United States, Asia or other manufacturing sites. We believe that there is only one environment and that this environment is global and worth protecting everywhere. The same applies when it comes to evaluating our employees’ workplace environment. Here, we make no compromises in maintaining high standards, true to our conviction that safety must have top priority – worldwide. We began more than ten years ago to validate all plants to EMAS environmental protection regulations and to have them certified to ISO 14001. In 2010, we reached this ambitious goal for all of our 70 production sites worldwide. Our commitment to environmental protection has gained recognition by our customers as well as political leaders. We have received the Ford Motor Company’s World Award for Environmental Leadership Worldwide multiple times. Receiving the Environmental Medal of the State of Bavaria, The European EMAS Award as well as the EcoGlobe in 2010 and 2011 serve as both a confirmation for our policy and a motivation to continue on our course. President and CEO of Schaeffler AG Company Portrait Company Portrait Schaeffler with its INA, LuK and FAG product brands develops and manufactures precision products for everything that moves – in machines, equipment, vehicles and in aviation and aerospace. Schaeffler is one of the world’s leading rolling bearing manufacturers and a renowned supplier to the automotive industry. In 2013, this globally active group of companies, which is headquartered in Herzogenaurach, Germany, generated sales of around 11,2 billion Euros. With over 78,500 employees, Schaeffler is one of Germany’s and Europe’s largest family-owned industrial companies. With 180 locations in over 50 countries, Schaeffler has a global network of manufacturing sites, research and development facilities, distributors, engineering offices and training centers. Customer proximity is important for developing market-specific products and fast service. All Schaeffler plants worldwide work according to the most stringent quality and environmental standards, and these plants have been certified to international standards. Through its “Code of Conduct” Schaeffler has committed itself to maintaining high social and ethical standards. Our Divisions Automotive The automotive industry is our main group of customers and represents 60 percent of sales. For this industry, Schaeffler is a recognized development partner with systems expertise for the entire power train – i.e. engine, transmission, chassis and accessory drives in passenger cars and commercial vehicles. Schaeffler offers a wide range of products that ranges from energy-efficient solutions for classic powertrains with internal combustion engines to products for hybrid vehicles to components for electromobility. Precision products made by INA, LuK and FAG help vehicles use less energy and emit fewer emissions without reducing driving comfort, safety and fun. Our customers worldwide include all renowned automobile manufacturers and suppliers. Our Automotive Aftermarket provides replacement parts in OE quality as well as comprehensive services to distributors and independent repair shops around the globe. It helps promote qualifications and expertise in brands and products and provides marketing support. CO2ncept-10% Study on reduction in fuel consumption and in CO2 emissions: ten percent less CO2 through consistent optimization of tried and tested technology |7 8| Company Portrait Industrial Through its global organization and application support teams close to the market, our Industrial Division supplies rolling and sliding bearing solutions, linear and direct drive technology in the INA and FAG brands for around 60 industrial sectors. Its products include more than 225,000 items, ranging from miniature bearings only a few millimeters in size, such as those used in dental drills, to large-size bearings with an outside diameter of several meters for wind turbines. The Industrial Division’s renowned “Aviation and Aerospace” group designs high-precision bearings for airplanes, helicopters and rocket engines such as the ones used in the Airbus A 380 and Boeing’s 787 Dreamliner. Special applications with high-precision bearings, e.g. in medical engineering, complete our product range. Schaeffler’s Industrial Aftermarket (IAM) handles the replacement parts and service business for end customers and distributors. IAM is a strong partner and offers its customers innovative products and services that significantly improve the service life and performance of production facilities. In addition to a comprehensive range of rolling bearing products, the IAM portfolio ranges from mechanical assembly tools to intelligent online monitoring systems, from service training courses to fully customized maintenance solutions. Company Portrait Success Factors Besides being close to the customer anywhere in the world, our strong employee focus and having sustainable management, other important success factors include innovative power and creativity. Around 6,000 employees develop new products, technologies, processes and methods at 40 development locations worldwide, including 16 R&D centers, to provide market-oriented solutions. With more than 1,800 patent applications and over 18,000 patents and patent applications currently in effect, Schaeffler is one of the innovation leaders in manufacturing. Our primary development locations in Germany are in Herzogenaurach, Schweinfurt and Bühl, all of which are linked to other development centers in Europe, Asia and North and South America. Growth through key trends Foresight as well as long-term thinking and actions are what characterize our company. Schaeffler identifies key trends at an early stage, invests in the research and development of new, future-oriented products, defines new technology standards and prepares these standards for volume production. In the areas of efficiency increase and CO2 reduction, renewable energies, mechatronics and e-mobility, Schaeffler offers a wide range of innovative products such as rolling bearings with optimized friction and performance, electromechanical components, rolling bearings with integrated functions and direct drives. The highly varied activities of the Automotive and Industrial Divisions with regard to electric mobility are concentrated in our “E-Mobility System House.” Our wide range of products already offers a multitude of solutions, ranging from sensor bottom brackets for electric bikes to start-stop systems and hybrid clutches all the way down to electric drives. Our Brands INA Founded in 1946 by brothers and Ph.D. holders Wilhelm Schaeffler and Georg Schaeffler in Herzogenaurach, this brand has become a global player as a rolling bearing manu facturer and automotive supplier. The INA brand primarily includes rolling bearings, linear systems and engine components. The success of this company with headquarters in Herzogenaurach began in 1949 when Georg Schaeffler developed the needle roller and cage assembly – an ingenious invention that helped needle roller bearings achieve their international breakthrough. In 1952, an INA-made needle roller bearing replaced the previously used plain bearings in VW Beetle transmissions and represented the beginning of an “automotive career.” Today, there are hardly any passenger cars without INA engine and transmission components. Cam phasers and hydraulic bucket tappets ensure higher performance, reduced consumption, fewer emissions and more driving comfort in modern engines. The high quality and reliability of its rolling bearings, engine components and linear technology products have made Schaeffler a sought-after and reliable partner for numerous industrial customers. |9 10 | Company Portrait The Schaeffler Site Schweinfurt, Germany FAG The FAG brand and the rolling bearing industry are inseparably linked. In 1883 Friedrich Fischer designed a ball mill in Schweinfurt that allowed him for the first time to produce high-precision steel balls in large quantities by machine. This invention is generally considered the historical beginning of the rolling bearing industry, which started its triumphant road to success in Schweinfurt. Ever since, FAG (Fischers Aktiengesellschaft) rolling bearings – a registered trademark since 1905 – have been synonymous with firstclass products and expertise. The Schaeffler Site Bühl, Germany Since its acquisition by INA-Holding Schaeffler KG in 2001, FAG has been an important part of the Schaeffler Group. Whether it is high-precision bearings for aviation and aerospace, sensor wheel bearings in passenger cars or large bearings with an outside diameter of more than four meters for wind turbines, FAG products are the first choice for all aviation and aerospace, manufacturing and automotive customers. FAG’s range of products and services is the perfect complement for the INA brand. LuK In the Schaeffler Group, LuK is the company that focuses exclusively on the automotive industry. LuK was cofounded by the Schaeffler brothers in Bühl in 1965 and immediately took the technological lead in the market with its first innovative product, a diaphragm spring clutch. The LuK Group has been fully owned by Schaeffler since 1999. A number of groundbreaking products followed, such as the selfadjusting clutch for dualmass flywheels and the dry dual clutch. Innovation and technological leadership are important company pillars. Today, one out of four cars worldwide has a LuK clutch. LuK works closely with its customers to find solutions for tomorrow’s automotive world. Examples include dual clutch transmissions and components for continuously variable transmissions, products that provide added safety and comfort and fewer emissions. Company Portrait Code of Conduct for Responsible Company Management Schaeffler is continuing the social responsibility of all of its companies and regards this as an essential requirement for continued corporate success. The Schaeffler Code of Conduct is based on the principles of the “Global Compact”, “The Global Sullivan Principles of Corporate Social Responsibility” and the standards of “Social Accountability International”. The basic principles described here constitute a minimum standard for us and do not affect countryspecific additions that are based on the relevant cultural circumstances. Human Rights We undertake to observe the internationally proclaimed human rights in our sphere of influence. Forced Labor We will not engage in or associate ourselves with any form of forced labor. Child Labor We will not engage in or associate ourselves with child labor in our operations. Discrimination and Respect of Others We mean to provide a workplace free of discrimination and harassment on the basis of gender, race, skin color, religious beliefs, age, national origin, handicap, or sexual orientation. Employees deserve each other’s respect. Compensation and Working Hours We recognize workers’ needs for adequate remuneration and observe the legally guaranteed minimum wages in the respective labor market. We observe the rules that apply to working hours in all of our operations. Relationship with Employees and Employee Representatives We respect our employees’ voluntary freedom of association. Independent of this, we also enable our employees to express their interests directly to management on a continual basis. Work-Life Balance We are a family-owned enterprise. With our family-friendly arrangements and provisions we strive to enhance the satisfaction and motivation of our employees and hence increase the performance of the Group. Health and Safety We mean to provide a safe and healthy working environment that meets or exceeds applicable standards for occupational health and safety. We will take steps to prevent injuries and occupational illnesses caused by workplace conditions. | 11 12 | Company Portrait Workforce Development We see the development of our employees as an essential investment in the future of our company. We also value the development of social and technical expertise. Environmental Responsibility We maintain an environmental management system at all production sites worldwide and continuously improve on this system. The minimum requirement is that local environmental protection laws and the specifications of the Schaeffler Group’s environmental protection system be observed. We collaborate with our business partners and suppliers in meeting our environmental responsibilities. Conflict of Interests, Gifts and Attempted Bribery We will not accept gifts or payments or hold (company) investments which could lead to a conflict of interests. In particular, neither bribes nor any other illegal payments may be offered, made or accepted. Suppliers We encourage, where practicable, our suppliers to introduce and implement similar principles of social responsibility within their companies. Responsibility We believe each of our employees has an individual responsibility to follow this Code of Conduct and encourage coworkers to abide by it as well. Management is responsible for enforcing principles that become part of our rules or policies. Global Environmental Protection | 13 Global Environmental Protection Over the past decade, Schaeffler has successively established an environmental management system that we can be proud of. All manufacturing sites have been certified to ISO 14001 and also to the more stringent European Eco-Management and Audit Scheme (EMAS). The Group’s non-European locations, e.g. in the United States, Brazil, China, India and Korea, have also successfully passed inspection based on EMAS. The certificates and environmental statements as well as the Schaeffler environmental policy are available on the Internet. With the validation and certification of its manufacturing sites, Schaeffler has been leading the way in environmental protection. The company has received several awards for this commitment, including the Bavarian Environmental Medal and has been awarded Ford Motor Company’s “Recognition of Achievement, Environmental Leadership“ award three times. Schaeffler’s commitment to environmental protection was recognized on a global scale when the company was presented with the EMAS Award in 2005. All of Schaeffler’s manufacturing sites have an environmental protection coordinator. At each location, the plant manager is responsible for ensuring environmental compliance. The “Competence Center for Safety and Environmental Protection” and its competence groups both plan and coordinate the strategic orientation of the management system and provide support on environmental protection issues to all Schaeffler Group locations worldwide. 14 | Global Environmental Protection Schaeffler Environmental Protection and Occupational Safety Policy Occupational safety and environmental protection are part of our management principles. We create and maintain a safe working environment that promotes the health and performance of our employees and embrace environmental responsibility to secure our company’s continued existence and success. The following principles apply to all Group locations worldwide. We are firmly committed to our employees, to society and to future generations. Efficient Occupational Safety and Environmental Management We embrace and continuously improve our occupational safety and environmental protection system. We develop forward-looking strategies and work with our business partners to implement these strategies. We perform regular checks to determine how well our specifications have been implemented and how successful our management system is in all divisions. A Safe and Employee-Friendly Workplace We believe that all work-related injuries and illnesses can be prevented. Highly motivated employees and executives support our efforts to provide a zero-accident workplace. We give equal consideration to the protection of our employees and contractors. That is why we base the design of new workstations and work processes on the latest scientific findings and place great importance on the ergonomic design of workstations. Global Environmental Protection | 15 Reliable Actions We are committed to complying with all legislation and specifications regarding occupational safety and environmental protection. We act responsibly in accordance with our own regulations, which often go above and beyond applicable laws. We plan, purchase, operate and maintain our machines and facilities using a strategy that helps prevent potential hazards and minimize risks and business disruptions. Our actions and decisions are based on state-of-the-art technology. Minimal Environmental Impact and Environmentally Friendly Products We take every effort to prevent environmental impacts in all of our activities. This includes our efforts to generate as little waste, wastewater, noise and other emissions as possible. We use resources and energy sparingly. We produce environ mentally friendly products by taking into consideration a product’s entire lifecycle. Responsible Employees We regularly provide information and training to our employees and business partners to ensure they have the skills and expertise necessary to carry out their work safely and to minimize environmental impacts in all company departments. Preventive Measures We take comprehensive measures to protect our employees from health hazards and prevent damage to the environment. Comprehensive and effective emergency measures are in place at all locations to ensure that our employees and visitors receive adequate care in the event of injury. Open Communication We conduct an intensive and trusted dialog with interested parties. We provide information about our occupational safety and environmental protection measures as well as the impact each of our locations has on the environment. President and CEO of Schaeffler AG 16 | Global Environmental Protection Environmental Communication The company’s intranet provides comprehensive information: contact persons, databases, a waste guide and much more. This information is made available to all employees worldwide. Company newsletters and notices are also used to inform employees. Regular Conferences Environmental protection conferences held every year allow participants to exchange in-formation and coordinate goals and actions. These conferences last several days and are attended by the environmental protection coordinators from all locations. Since environmental protection conferences were first introduced, cooperation and coordination (e.g. for planning environmentally relevant facilities) between all locations have improved tremendously. Global Regulations: Plant Standards and Procedures All actions relevant for the environment, such as the approval of indirect materials or the specification of substances prohibited for use in products and packaging, are regulated globally by special plant standards. In this way, Schaeffler ensures that hazardous materials are used only if there are no other alternatives. The relevant departments are informed in a timely manner about the use of such materials, and the required action is taken. This means that our customers can be sure that products supplied by Schaeffler contain only approved materials. Safety rules and regulations also apply to contractors working in Schaeffler plants. A document detailing all safety-related requirements has been prepared for contractors working on the plant premises. Contractors may not enter the premises to perform their work unless they have agreed in writing to comply with these requirements. Regular Internal and External Audits The level and progress of the company’s environmental protection are also monitored by regular internal audits at all manufacturing sites as well as external audits by an independent environmental verifier. These audits are planned and coordinated at company headquarters and carried out by the Schaeffler auditor pool. All locations receive an audit report that includes details of the current status and recommendations for improvement. Due dates and responsibilities are defined for all relevant measures. Global Environmental Protection | 17 2011 EcoGlobe Awarded to Maria-Elisabeth Schaeffler Maria-Elisabeth Schaeffler receives 2011 EcoGlobe Person of the Year Award The EcoGlobe Institute of the University of Duisberg-Essen has awarded the 2011 EcoGlobe Person of the Year Award to Maria-Elisabeth Schaeffler. The prize was awarded in honor of Mrs. Schaeffler’s entrepreneurial achievements and cultural and social commitment as a company partner, Vice Chairperson of the Schaeffler AG Supervisory Board as well as a member of the Supervisory Board at Continental AG. “Her keen sense of what is good for the company’s employees and with great selfdiscipline, has allowed Maria-Elisabeth Schaeffler to build a business that has a highly remarkable corporate culture and great economic success,“ the selection committee said in its statement. The strategic principles to which Maria-Elisabeth Schaeffler has oriented the company are characterized by high social, environmental and quality standards. She has molded the group into a modern, global and successful family-owned business and given it a very sound strategic direction.“ The committee especially stressed Schaeffler’s activities in the fields of sustainability technologies, including the optimization of tracking systems for solar plants, the development of wave energy converters for the utilization of ocean power and drivetrain solutions for wind turbines as well as the company’s dedication to electric mobility and its contribution to reducing fuel consumption in internal combustion engines. At the awards ceremony Maria-Elisabeth Schaeffler said, “It is my great pleasure to accept the EcoGlobe Person of the Year Award. I regard it not only as recognition of what I have done in the 15 years since my husband passed away, but also a confirmation and appreciation of Schaeffler’s great technological achievements.” The EcoGlobe, initiated in 2007, is the mobility industry’s first international environmental award. Under the patronage of the Environmental Minister of the Federal Republic of Germany, it is sponsored by DEVK Versicherungen and ACV Automobil-Club Verkehr in cooperation with the EcoGlobe Institute Duisburg-Essen and awarded by an independent blue-ribbon committee consisting of experts from the fields of science, politics, business and culture. Professor Ferdinand Dudenhöffer presents Maria-Elisabeth Schaeffler with the 2011 EcoGlobe Award 18 | Environmentally Friendly Products Environmentally Friendly Products Environmental pollution and the depletion of resources can largely be attributed to the increased consumption of products. We must change our way of thinking and insist on environmentally friendly products that use fewer resources and minimize the strain on the environment. Our “Integrated Product Policy (IPP)” addresses this idea and aims to promote environmentally friendly products. Schaeffler – Always One Step Ahead This isn’t a new idea for Schaeffler; we have embraced this idea for many years. We accepted the challenge to design environmentally friendly products a long time ago. What is new is the methods and tools used to achieve this goal. How can we utilize previously untapped potential to improve the ecobalance of a product over its entire lifecycle? New Inroads One way to make environmentally friendly products is to increase the efficiency of the material and energy used, thus reducing environmental impacts. We continuously evaluate and design all material and energy flows, from the time they enter the company to the time they leave as products or residual materials. Comprehensive Data Management The company’s own environmental data coordinator handles inputs and outputs of material and energy flows for all processes and products at the respective plant. Material flow analyses help further integrate environmental management into the company’s corporate units, such as Logistics, Manufacturing and Financial Controlling. Existing processes and technologies are questioned thoroughly, and additional opportunities for improving processes are recognized and put into practice. Information Networks Environmental impacts occur even when resources are extracted. To make products even more environmentally friendly, Schaeffler stays in close contact with its suppliers and customers. A shared network is used to record and analyze environmental information along the entire product chain. The insights gained allow new solutions to be recognized for environmentally friendly products and sustainable development. Recycling We try to ensure that manufactured components are recycled at the end of a vehicle’s service life. This is why LuK and INA are founding members of the Partslife recycling system. Social Responsibility | 19 Social Responsibility Environmental experts around the world agree that the global environmental problems of our time can only be solved if both economic and social factors are considered. On the one hand, only economically healthy companies pursue long-term environmental protection activities, and from a social standpoint people who are starving or suffering social injustice cannot be motivated to become active in protecting the environment. The “principle of sustainable development” is based on these assumptions. In line with the company philosophy of accepting new challenges, Schaeffler has tackled the concept of sustainability. Generally, sustainability is not seen as an additional job to be completed but as an idea that offers new opportunities since it links problems that were previously treated separately. A view that integrates economic, ecological and social issues allows new solutions to be found and thus contributes to the sustainability of a company and of society as a whole. Although a lot has been said about sustainability and social responsibility, not a great deal has been done. The examples below show that things are different at Schaeffler: Health as a Social Factor Preventive occupational health and safety represents an essential social component at Schaeffler. We confront this responsibility by implementing numerous measures and projects. Preventive medical check-ups, workstation inspections and medical workplace consultations, reintegration support after long illnesses and fast medical help in emergencies are only some of the many services our Medical Services team provides. We also offer a wide range of company sports groups. Apprenticeships and Professional Training for Future Needs With around 3,000 apprentices worldwide and high-quality vocational training, Schaeffler has a role model function. Schaeffler employees can make use of a comprehensive range of continuing professional training courses to keep their skill sets up to date or for their personal development. Retirees are Still Part of It All Even after our employees retire, they have a number of opportunities to stay in touch with their company. Social security, justice and consideration, training and company pension plans aren’t just empty phrases. The Group does its part to benefit society, putting it on the right track in its efforts to achieve sustainability. Social security, justice and consideration, health protection, educational opportunities and company pension schemes are not just hollow phrases at Schaeffler. Our company expresses its solidarity with society, putting us on the right track to sustainability. 20 | Location Presentation of the Calais Site Workforce data (total workforce) as of 30/09/2013. SCDS Temporary Workers SCDS Permanent staff SCDS Fixed-term staff Total Direct 129 5 163 297 Indirect 7 2 129 138 General total 136 7 292 435 We currently have a large number of temporary staff working at the site to compensate for start-up delays and heavy demand. Total area and built area at the site The SCDS site is located in the Marcel DORET urban development zone, rue Louis BREGUET in CALAIS (62), in premises which were previously occupied by BELLIER et CIE. The total surface area of the site is 41320 m2, distributed as follows: >>builton area: 15500 m2 >>covered area (other than builton): 10450 m2 >>open area (green spaces, …): 15370 m2 Products The company SCHAEFFLER CHAIN DRIVE SYSTEMS is involved in the design, testing, manufacture and sale of distribution systems for the auto industry, under the INA brand name. We mainly make roller chains, roller bush chains and inverted tooth chains, of a variety of dimensions and specifications. Examples of the types of chains we make Location Production processes The diagram below shows the general methods used in the manufacture of chains. Manufacture of bushes and rollers Manufacture of pins Manufacture of plates (interior, median, exterior) Assembly Chains The first stages include the manufacture of plates, axles and bushes. These components are then assembled to form the chain. On-site facilities Below we describe some of these standardised production facilities, the site includes: Three large production areas (components, thermal treatment and assembly), raw materials storage area, shipping area, areas for ancillary activities (tooling, compressor, gas and consumable product storage, maintenance shop and laboratory, transformer zone and two office and administration zones). Each of the diagrams below includes photos of each installation as well as outgoing and incoming lines (power, raw materials, rejects and finished products). | 21 22 | Location a.Plate cutting operations: These operations are performed on the raw materials by mechanical presses Energy: Electricity (400 V) Compressed air (6 bars) CE machines conforming to regulations. Periodic regulatory preventive maintenance visits for equipment PRESSES process Plate cutting from flat steel rings Operating temperature: Ambient Raw materials: >> Steel ring >> Oil; Martol (Automatelf ) EL 78: (Total) Waste: >> Falling steel or scrap >> Oil vapour (filtration of vapours by electrostatic filter) >> OIW (paper) >> SIW (cloths, oily absorbent Finished product: >> Plates with burrs b.Rolling operations: The rolling operation includes: precutting of a metal strip, forming the strip into a “U” shape around a mandrel, and closure of the “U” shape to achieve an “O” shape, which is then calibrated in a drawing die. Energy: >> Electricity (400 V) >> Compressed air (6 bars) Machines compliant with decree 93-40 ROLLING process Metal transformation processes: rolling around a mandrel and punching of bushes and rollers Operating temperature: Ambient Raw materials: >> Steel >> Martol oil >> (Automatelf ) FI 85: (Total) >> EP CRANKCASE >> 150 (Lubrication): (Total) Waste: >> Falling steel or scrap >> Oily residues >> OIW >> SIW Finished product: >> Bushes >> Rollers c.Tribo-finishing Tribo-finishing involves several stages: degreasing, tribo-finishing or deflashing, and then rinsing. Energy: >> Electricity (400 V) >> Compressed air (6 bars) CE machines conforming to regulations Periodic regulatory preventive maintenance visits for equipment Raw materials: >> Parts for deburring (plates, bushes) >> Water >> Ceramic abrasives: Rosler) >> Corn cob media (Tribogrit) (Rosler) >> composed: ZF322 S: (Rosler) ROSLER process operation involving deflashing and cleaning of untreated components Operating temperature: Ambient ROSLER centrifuge and powder flocculant AR7120 (Rosler) bactericidal liquid flocculant AR 8405 (Rosler) Ebotec & Cilon (Rosler) Waste: >> Water & oily residues >> Centrifuged sludge >> Rejects (steel) >> OIW (paper, plastic) >> SIW >> diffuse dust (extractor filter) Finished product: >> Deburred parts Location d.Drum abrasion The parts are placed in a drum with abrasives to remove mill scale and to produce polished shining surfaces. Energy: >> Electricity (400 V) Charged treatment water DRUM ABRASION process final cleaning and deflashing process for components before assembly / Operating temperature: ambient Raw materials: >> Lapping compound (rosler) >> Tribolite L 320 (rosler) >> ZF 311 (rosler) >> Carbofast >> degreaser R 36 (rosler) >> Ceramic abrasives (rosler) >> Town water Purified water ROSLER centrifuge and flocculant powder AR7120 (Rosler) bactericidal liquid flocculant AR 8405 (Rosler) Waste products: >> Water & oily residues >> Drum abrasion slurry: >> OIW >> SIW >> Recycled water used depends on frequency of purges Finished product: >> Finished components for assembly e.Thermal Treatment by Diffusion hardening The pins are placed in diffusion hardening ovens with a mixture of ammonium chloride (powder) and ferrochrome (powder). A reaction between the carbon in the part and chromium chloride forms chromium carbides. Gas energy: Electricity 400 V Compressed air: 6 bars Natural gas 1.5 bars Raw materials: >> Parts to be treated >> Ferrochrome powder 21,500 Kg/year >> Ammonium chloride 175Kg/year (Univar) >> Alumina (Abrasive) >> Nitrogen for safety purge >> Argon 8001 h at 1.5b DIFFUSION HARDENING Process Deposition of a fine layer of chrome on the pins which is highly resistant to wear Operating temperature 960 C Waste products: >> Ferrochrome powders >> Fumes >> Quenching oil >> OIW >> SIW >> Rejects (steel) Finished product: >> Treated parts f.Thermal Treatment via Carburization The parts to be treated are placed in carburization ovens in which the atmosphere comprises endothermic gas, ammonia and propane. Gas energy: >> Electricity 400 V >> Compressed air (6 bars) >> natural gas 1.5 bars >> Nitrogen 1.5 b only for safety purges Raw materials: >> Steel >> Oil, DRASTAC 1000 (TOTAL) >> propane: 200 l/h at 1.5 b >> ammonia: 200 l/h at 1.7 b >> Nitrogen 3000 l/h at 1.5 b CARBONITRIDING process addition of carbon to the surfaces of treated components followed by oil quenching to harden the surface. Operating temperature 860 °C. Waste products: >> Falling steel or scrap >> Oily residues >> OIW >> SIW >> ducted atmospheric waste End product for correction: >> Pins | 23 24 | Location g.Isothermal hardening Each of the 3 hardening lines comprises: >>A heating zone which raises the temperature of the parts to between 850 and 900°C. >>A salt bath (a mix of sodium nitrate and potassium nitrate) maintained at a temperature of 345°C. >>A water bath for rinsing the parts. >>A dryer for drying the parts. Energy: >> Electricity (400 V) >> Compressed air (6 bars) and >> Endothermic gas (14 m3/ h at 70 mb) >> Natural gas (from 400 to 1200 L/h) at 1.5 b >> Nitrogen (8m3/h at 1.1 bar during safety purges) or >> Nitrogen: 5600 l/h at 1.5 b >> Methanol: 5 l/h at 1.5 b >> propane 400 l/h at 1.5 b >> Nitrogen (8m3/h at 1.1 bar during safety purges) Raw materials: >> Durferrit salts AS 140 (Durferrit) >> Water >> Corn cob media (Tribogrit) (Rosler) >> Parts to be treated plates, bushes and pins DELEMOND process tempering oven with salt bath for treatment of pins, rollers and plates used for tempering components Operating temperature: 880°C. Muffle 220°C at 340 C salt bath Waste products: >> Waste salt >> ducted burnt gas >> Rejects (steel) >> OIW >> SIW >> Tribogrit dust >> (special filtration by filter pockets) End product for correction: >> Pins Information about the surrounding area The site is located in the Marcel Doret urban development zone, this area is home to a number of companies performing a variety of different activities. The area is largely conditioned by the presence of these companies. There are no buildings protected under the Historic Monuments act within a radius of 500m around the SCDS site. The site is not situated within a ZNIEFF (Zone of Natural Ecological Fauna and Flora Interest). The nearest ZNIEFF is situated 530 m from the site. Location The main modifications made to the site New and renovated buildings It was not without some sadness that the shutters at Boulevard Lafayette were closed on the 2nd of August 2013, it had been operation for a hundred years and thousands of people from Calais had worked there at one time or another. The keys were officially handed over in the presence of the plant manager, who is seen posing with the representative from Renold at the site. In fact, the move to the site at 1000 rue Louis Bréguet began in the middle of December. By the end of July all machinery required for production had been installed. This move had significant benefits both from a point of view of safety and the environment. >>Access for delivery trucks is far easier at the new site as it is in an industrial zone and close to the Motorway. At the other site, lorries were required to circulate around the centre of the town, close to schools, shops and houses. >>Installation of a water storage tank: The water storage tank has two purposes. Firstly it is designed to store rainwater falling on the buildings, car parks and roads and to release it into the external sewer system slowly to prevent flooding from overloading of the town sewer system. The internal drainage network was therefore mostly renovated in order to drain all rain water into this tank. The tank is fitted with a hydrocarbon separator in front of the inlet which filters out any residues before the water is sent to the external sewer system. The second goal is to isolate the site in the event of pollution or fire. New production machines >>ROBOTISED FINISHING LINES Two new Robotised finishing lines have recently been entered into service: The first, at the end of July, the second came online in August | 25 26 | Location These machines were designed and manufactured by a specialized company, located on the Opal coast, in close cooperation which the SCDS mass production department and will help us to increase our production capacity for these types of chains. COMPOSITION OF THE MACHINE: >>The chain is closed by a robot (1), as on existing lines. >>There are two closing stations (2), the first for clasping middle plate and the second for the outer plate. >>The pin riveting station (3) and chain advance station (4) are the same as the current robotised lines. >>A pad printing station (5) will be installed to mark the chains. >>The Quality Control station includes industrial vision systems (6) equipped with 4 cameras. This station oversees the quality of the chain assembly, the correct application of paint markings and the presence of all components of the chain. >>Chain length measurement station (7). This controls the length of the chain between axles. >>A chain sorting module (8), situated at the end of the line, dispatches the chains into the appropriate boxes based on the results of the various checks. >>Lubrication station (9). Compliant chains are sent to a machine in which they are sprayed with oil to prevent oxidation during transport to the client and subsequent storage. Following observations on our existing lines made by the HSE and production departments, we have made a number of ergonomic improvements to our major lines (list is Location not exhaustive): >>The height of the control panel can be adjusted to suit the operator. >>Boxes at the output of the machine are more accessible. >>An oil mist filter system has been fitted to the chain lubrication machine. Relocation of machines, products and materials Relocating the site obviously also required relocation of the machines, to do this the HSE department approved a consignment of all machines. This was followed by reinstallation of the machines at the new site. Use of new technologies Relocation to the Marcel Doret urban development zone has allowed us to make significant changes to increase protection levels both for the environment and our staff: >>REDUCED WATER CONSUMPTION: They hard drum abrasion sector at the Boulevard Lafayette site was connected to an open water circuit; water from the drum abrasion process is now sent to a buffer tank which is pumped out on a regular basis. At the new site, this sector will be equipped with a water treatment system which is similar to that currently in use in our tribo-finishing system. This is an environmental requirement and has allowed us to make significant water consumption savings. We have been able to reduce our water consumption to a third of what it was. >>OVEN EXTRACTION SYSTEM: The oven extraction systems have been completely redesigned to allow them to capture fumes at their source. Diffusion hardening ovens will now be fitted with four extraction points located at the outlets of each unit, they will be smaller than those we had at Bd Lafayette. The increase in the number of extraction points and the reduction in their size will increase flow rates and subsequently improve the efficiency of the system. Waste diffusion hardening products are first treated by a dust filter before passing through a charcoal filter to be discharged to the exterior via one of the 4 chimneys constructed at the new site. | 27 28 | Location Organisational modifications >>APPOINTMENT OF A NEW PLANT MANAGER After 22 years at the company, the plant manager announced that he was leaving the Schaeffler Group to take his professional career in a new direction. The Schaeffler Group appointed a new plant manager as his successor. He officially took up his new position on the the 3rd of January last year. >>APPOINTMENT OF A NEW PRODUCTION MANAGER To succeed former production manager, who announced his intention to resign, the Schaeffler Group appointed his successor, who has held the post of Production Supervisor since the 21st of January (Manufacturing, Maintenance, Tooling). Environmental Impacts Direct Environmental Impacts Regulatory requirements and authorisations The SCDS site is subject to a Prefectoral authorisation permit dated 24 March 2013. Below is a list of the installations falling under the section on nomenclature of classified installations: Plain text name of the installation Characteristics of the installation Classification section AS, A, D, C Mechanical working of metals and alloys, installed power of all fixed static machines required for operation of the installation being greater than 500 kW. Installed power: 775.05 kW >> 5 presses: 471 kW >> 42 rolling machines: 42 kW >> 4 dryers: 18 kW >> Miscellaneous tools: 143.3 kW >> Rectification plant: 102.75 kW 2560-1 A Industrial heating and treatment Thermal treatment shop using molten salt baths, the volume including 4 ovens. of the baths being greater than 500 Volume of salt baths: 31,300 l litres. 2562-1 A Use or storage of solid toxic substances and preparations, the total quantity likely to be present in the installation being greater than 5 t but less than 50 t. 15 tonnes max. 1131-1-c D Use and storage of ammonia. Ammonia: 315 kg 1136-A-2-c D Storage and use of substances and 29.62 t max preparations which are highly toxic to aquatic organisms. 1172-3 D Inflammable liquids (storage in tanks made from) covered by section 1430. Equivalent storage capacity of inflammable liquids of 37.7 m3 including: Storage of 30 tonnes of methanol, or 37.5 m3 1432-2 D Hardening, annealing and tempering of metals or alloys. Quenching baths and tempering ovens. Volume of quenching oil baths: 21,000 l 2561 D 2565-2-b D D Metal coating or surface treatment 2 detergent degreasing machines using electrolysis or chemistry, pro- - total volume of treatment tanks: cedures using liquids, the volume 1300 l of treatment tanks being greater than 200 l but less than 1,500 l. Metal coating or surface treatment using electrolysis or chemistry, treatment in gaseous phase. 6 chroming ovens 7 carburization ovens 4 baths upstream of the salt baths 2565-3 Use of abrasive materials on any type of material, the installed power of all fixed static machines required for operation of the installation being greater than 20 kW. Tribo-finishing installations: 122 kW Shotblasting installations: 25 kW Drum abrasion installations: 74 kW Giving a total of 221 kW. 2575 Fluorinated greenhouse gases Cumulative quantity of fluid likely covered by Regulation (EC) n° to be present in the installation 842/2006 or substances which lower than 300 kg. damage the Ozone layer covered by Regulation (EC) 1005 /2009 (manufacture, use, storage). 2-a) Use in operational enclosed equipment. A (Authorization) or D (Declaration) or NC (Not Ranked) 1185-2 NC | 29 30 | Environmental Impacts Plain text name of the installation Characteristics of the installation Use and storage of oxygen. Total quantity of oxygen likely to be present at the site: 10 kg. Liquefied flammable gas (storage Total quantity of propane likely to in tanks made from), with the be present at the site: 3200 kg. exception of those specifically covered under other sections of the nomenclature. Classification section AS, A, D, C 1220 NC 1412-2 NC Acetylene (storage or use of the) Total quantity of acetylene likely to be present at the site: 18 kg 1418 NC Storage of combustible materials, products or substances in quantities greater than 500 t in covered depots, excluding depots used for the storage of categories of materials, products and substances already covered by this nomenclature, buildings used exclusively for the storage of motor vehicles and trailers, premises open to the public and cold storage depots. The quantity of combustible materials present at the site is less than 500 t. >> Raw materials buffer storage zone: 61 t, >> Shipment zone: 57 t, >> Consumable products zone: 27 t. 1510 NC Depots for the storage of paper, cardboard and similar flammable materials. Depots for the storage of dry wood and similar flammable materials. Maximum volume of cardboard likely to be stored at the site: 300 m3 1530 NC Maximum volume of wood likely to be stored at the site: 200 m3 1532 NC Storage of tyres and products, at Maximum volume of plastic mateleast 50% of the total unit mass of rials likely to be stored at the site: which comprises polymers (plastic 600 m3 materials, rubber, elastomers, resins and synthetic adhesives). 2663-2 NC Combustion, excluding installations covered by sections 2770 and 2771: when the installation exclusively consumes, alone or mixed with other substances, natural gas, liquefied petroleum gas, domestic heating oil, coal, heavy fuel oil or biomass. For heating, the site will be equipped with: >> 24 gasfuelled heaters with an output of 70 kilowatts, or 1,680 kW in total. >> 1 gas boiler Maximum power rating of all installations is less than 2 MW. 2910-A NC Battery charging shop. The maximum DC current power used for this operation being greater than 50 kW. (D) For heating, the site will be equipped with: Maximum power rating of usable DC current: 42.2 kW 2925 NC A (Authorization) or D (Declaration) or NC (Not Ranked) Emissions Emissions of polluting gases arising from our production processes are limited and essentially come from the ventilation of our shops, combustion gases coming from natural gas thermal treatment installations. The company has four waste product stations, which are monitored on a biannual basis by a specialist company. These four stations are connected to our thermal treatment installations (Chroming, Carburization, Isothermal Hardening and endothermic Generators) Environmental Impacts Water preservation The water at the site is fed solely from the public network. This water is mainly consumed for washing equipment and floors and for use by staff (sanitation) and processes. The sewer system is of the dualwater type. It comprises two distinct networks for the collection of waste water (sanitation...) and the collection of rainwater. Rain water passes through a hydrocarbon separator before being sent to the communal rainwater collection network. Subsequent investment has been made to allow some installations to operate on a closed circuit. Example: To cool water passing through the turbines, siphons and the return channels of the Delemonts, two cooling units have been installed meaning that the public water supply no longer has to be used. Furthermore, on water treatment installation has been installed in the drum abrasion sector allowing it to operate on a closed circuit. Industrial waste water from the site is collected and removed as a waste product by an authorised external company. Waste product management General management of waste products is managed by the HSE department under the responsibility of the head of the site. The HSE department makes sure that waste products are sent to the appropriate treatment centre and handles administrative tracking, they also make sure internal regulations are complied with. Each department head is in charge of compliance with instructions for managing the waste generated by their department. The main waste products generated at the site include: >>Scrap steel and production waste products >>Soiled corn cob media >>Soluble oils and washing water >>Neat oils (hydraulic oils, stamping oils...) >>Tribo-finishing and rectification slurry >>Used ferrochrome powder >>Used hardening salts >>Packaging cardboard, paper and plastics >>Harmless industrial waste: (plastics, cups, “household waste”, miscellaneous waste not soiled with oil). >>Wooden pallets | 31 32 | Environmental Impacts Other waste products generated in small quantities are treated individually (batteries, aerosols, electronic equipment, oily sludge, filtration resins...) and subject to special shipments depending on the quantity. Internal incineration of waste products is strictly prohibited, as well as burning them in the open air and all forms of tipping. Decontamination In connection with the relocation of our business, Schaeffler, the tenant of the RENOLD site located in the city centre of Calais, has appointed an external company speciali zing to oversee the retirement memorandum. In a letter of 13 May 2013, we notified the Prefect of the cessation of business at our site located at 188, Boulevard Lafayette in Calais (62100) on 1 August 2013. In compliance with Article R512-39-2 of the Environmental Code, we sent the cessation of business memorandum to the Prefect at the end of July. The company RENOLD, owners of the land, and the Calais Mayor’s Office, responsible for urban planning, also received a copy of this letter. SCHAEFFLER CHAIN DRIVE SYSTEMS proposed that this land is used for Classified types of Installations in the future, the operation of which is compatible with the presence of inhabited dwellings and with existing infrastructure, as specified in the regulations associated with the Local Urban Plan of the city of Calais. The use of natural resources and raw materials (water, electricity, gas, fuels, raw materials etc.) Measures are implemented on an ongoing basis to limit water requirements at the various sites as far as is possible, this has allowed us to reduce our overall water consumption to a third of what it was over ten years. The boiler installations in the various sectors mostly operate using natural gas, a fuel which releases significantly less emissions into the environment compared to other types of fuel. Use of raw materials, consumables, semi-finished and purchased products We prioritise the use of environmental friendly products. All chemical products used at our site are properly identified and managed. Sheets for these products are disseminated to all users. They indicate the hazards, prevention measures and steps to be taken in the event of accidents, as well as storage and handling procedures. Maintenance and upkeep Maintenance is handled by several departments which are in charge of repairs, improvements and preventive maintenance for some 700 machines at the SCDS factory. Environmental Impacts The Boilermaker/Maintenance department handles welding, sheet metalwork, machine installation, manufacture of protective guards etc. The 9 staff in the Mechanical department and 8 in the Electrical department handle day-to-day repairs (Corrective Maintenance), Level 2 Maintenance (Preventive) and improvements and modifications to machines (Level 3 Maintenance) when manufacturing new chains. The mechanical technicians are involved in a number of areas and must have solid skills in mechanics, hydraulics and pneumatics. Electricians require a good grounding in electrics, as well as automation as we use automated machines from a number of manufacturers at our factory and each has its own characteristics and programming language. They also look after artificial vision systems (camera control) and regulation (gas, thermal treatment temperatures...). The Methods and Maintenance department (1 technician) designs and schedules preventive maintenance plans (Levels 1&s) based on information provided by machine manufacturers, fault histories and feedback from the maintenance department. He also looks after Infrared thermography, which is used to detect, correct and prevent anomalies and defects in electrical components. Risks associated with accidents and environmental impacts which may result in incidents, environmental accidents or potential emergency situations. The organisational system in place at the site is more geared towards prevention. Procedures have been implemented in such a way that new activities and modified activities are analysed in order to determine if they are likely to have an environmental impact. The site is equipped with a smoke detection system and fire alarms and critical installations are also equipped with gas detectors. Two stations (gas and fire) handle triggering of alarms which are centrally linked to the guard station and maintenance department for rapid response times. Transport and logistics In order to minimize traffic we now only use a single transport company for small packages and urgent deliveries. Our clients require that we use their transport companies. When the transport company is also a supplier, we optimise transport arrangements by combining our shipments with those of the client. | 33 34 | Environmental Impacts For logistics within the factory, we are working on implementation of a logistics train, a concept which was initiated at the previous site for assembly lines and which has now been rolled out throughout the assembly sector. The logistics train handles transport of incoming goods (components, MCO, packaging materials). This allows us to limit the number of trips made within the factory and reduces the number of crates stored in the shops. Impacts on biodiversity The site is located in the Marcel Doret urban development zone and does not fall within a ZNIEFF (Zone of Natural Ecological Fauna and Flora Interest). The closest ZNIEFFs are: ZNIEFF n° 231 located 530 m to the East of the site, and ZNIEFF n°73 located 1.1 Km to the North. An impact study was performed by an external provider before we moved in, it concluded that impacts are considered as limited. Environmental Impacts Indirect Environmental Impacts Products and Packaging (Design, development, usage, recycling, transport, etc.) Finished product packaging is mostly specified by the client and includes filmwrapped pallets, reusable plastic bins, reusable wooden crates and recyclable cardboard boxes for other clients. Impacts associated with the products During the design stage When designing products, Schaeffler France always complies with restrictions on the use of products which are prohibited by national and European legislation, as well as those listed by the car constructors’ association. On the one hand, no product may be purchased or used without having been approved in the quality assurance procedure implemented by the Schaeffler Group. This procedure limits the environmental and human risks associated with products to a minimum. During the application stage Schaeffler products for cars are specially designed to reduce fuel consumption and subsequent emissions of pollutants. At end of life Our products are mostly made from steel and do not contain hazardous materials. They can therefore be recycled at the end of their lives without problem. Employee transport Having moved the factory from the centre of the town to an industrial site in the suburbs, we have worked with CAC (Communauté d‘agglomération du Calaisis) to implement measures to limit the use of cars by our employees (and the atmospheric emissions associated with this): >>Public transport: There is a bus stop close to the factory which reduces car traffic. >>VEL’IN service: This free loan service is a part of the SITAC public transport network. Ecological, practical, economical and healthy, the Vel’in service provides an alternative mode of transport for travellers. One of these stations has just been set up at a distance of 50 m from the factory. Environmental performance of external companies, suppliers and sub-contractors We have chosen to prioritise more environmentally-friendly suppliers over similar other ones (environmentally certified and those which have made environmental commitments). Furthermore, we have imposed certain standards on our suppliers in terms of substances which are prohibited for Schaeffler France products and packaging materials. Activities undertaken by external companies at our site which may have an environmental impact are taken into account in our prevention plans. Environmental impacts associated with procurement procedures Raw materials are delivered on wooden pallets which are stored and then sent back to suppliers on a rotation basis. The same applies to wooden inserts. | 35 36 | Health and Safety Risk Management FIRE SAFETY Internal fire services Training sessions in the use of fire extinguishers are provided on a regular basis. Extinguishers Portable fire extinguishers and hose systems are distributed over the entire site. To make these extinguishers more visible and accessible, safety stations have been installed at each end of the corridors in the assembly sector (see photo attached). For other sectors with more specific risks, extinguishers have been judiciously installed based on the risks present. Training / Exercises Staff supervising maintenance and Thermal Treatment processes are trained in the actions to be taken when a fire alarm is triggered. This training allows staff to react more effectively in the event of an alarm and when there is real danger. General evacuation exercises are conducted at least once a year to allow staff to get used to the sirens and to practice evacuation drills. Fire water retention A fire water retention basin has been constructed to buffer rain water coming from the buildings... but also in order to isolate the site in the event of pollution or fire. The water used to extinguish a fire will obviously be polluted. This tank therefore allows us to keep polluted water at the site before it is removed by a qualified company. An extension to this tank has been budgeted for in order to meet the standards imposed by Prefectoral legislation. Security The site is entirely fenced. A security company is in charge of controlling access to the site. Management of external companies All external companies conducting work at the site must present themselves at the guard station and received permission from an SCDS manager to work at the site. The Security/Environmental department are in charge of creating a prevention plan before significant or dangerous work is carried out. Health and Safety Controls (Transport of hazardous materials) Safety responsibilities for the transport of hazardous materials have been entrusted to an external provider. They make a technical visit once per year and write up a report based on this. They also provide assistance with any regulatory modifications and issues relating to the transport of hazardous materials. Each transport operation is controlled to check compliance of the transport company and the goods in regard to the regulations. These checks are performed internally by staff members who have been trained in ADR. | 37 38 | Health and Safety Safety at work Presenting safety, ergonomics, hygiene, health care at work and implementation at the site. >>Safety at work In order to reduce accidents as far as possible, a risk assessment is updated on a regular basis, this is done using a software package which allows us to identify risks and implement corrective actions. Following an accident an inquest is conducted to prevent its reoccurrence, this will involve the operator, the supervisor and the HSE department. The graphs below illustrate a drop in the number of serious accidents thanks to the various measures we have implemented. Changes in the frequency II rate since 2008 60 50 40 30 Target Trend curve 20 National average 10 Frequency rate = Trim 2013 Trim 2013 Trim 2013 Trim 2013 Trim 2012 Trim 2012 Trim 2012 Trim 2012 Trim 2011 Trim 2011 Trim 2011 Trim 2011 Trim 2010 Trim 2010 Trim 2010 Trim 2010 Trim 2009 Trim 2009 Trim 2009 Trim 2009 Trim 2008 Trim 2008 Trim 2008 Trim 2008 0 Number of accidents involving a work stoppage x 1,000,000 Number of hours worked Changes in the seriousness II rate since 2008 1.80 1.60 1.40 1.20 National average 1.00 0.80 Target 0.60 Trend curve 0.40 0.20 Seriousness rate = Number of stoppage days x 1,000 Number of hours worked Trim 2013 Trim 2013 Trim 2013 Trim 2013 Trim 2012 Trim 2012 Trim 2012 Trim 2012 Trim 2011 Trim 2011 Trim 2011 Trim 2011 Trim 2010 Trim 2010 Trim 2010 Trim 2010 Trim 2009 Trim 2009 Trim 2009 Trim 2009 Trim 2008 Trim 2008 Trim 2008 Trim 2008 0 Health and Safety >>Work station ergonomics The Methods department integrates ergonomics in to the design and modification of work stations. Work stations are reviewed on a regular basis by a specialist in “movement and posture” in occupational medicine. A working group has been set up to improve the ergonomics of work stations at the factory, below is an example of one of the measures implemented: Bin transport improvement process All finished cut plates delivered by an external provider are stored in blue plastic bins. In order to feed our tribo-finishing machines with components, the contents of the plastic bins must be transferred to metal containers. This operation is difficult as the transfer is done manually and the bins are heavy. We have implemented a new method for performing the transfer which is far easier and less restrictive. It also allows 4 bins to be loaded at a time and the bins can be changed without physical effort. >>Health at work A nurse is present at the site on a full-time basis. There are also Rescue staff at the site, distributed throughout the teams, who have been trained in administering first aid after an accident. Rescue staff are rotated on a regular basis. The occupational physician is on site at least one day per week. All new hirings must undergo a medical check, as well as those restarting work after a long break. All production staff must have a medical check at least once a year. The occupational physician may request special tests (X-rays, blood analysis...) and prohibit staff from performing certain tasks. | 39 40 | Health and Safety Social Aspects In order to meet our social obligations and to create a good social dynamic, SCDS has taken significant measures. We have chosen an innovative policy, particularly in regard to employment and social aspects. We believe it is essential to anticipate and guide the development of our staff in order to improve their employability in highly competitive surroundings. The Group’s HR and social policy combines economic development with social advancement. We develop the skills and know-how of our employees and our partners through regular information and training sessions which may be ongoing or not, both to promote safety at work and to protect the environment, applying to all departments of the company. SCDS has signed several corporate agreements and has developed a voluntary policy relating to the working conditions of employees and staff: >>agreement on the employment of seniors >>committee on psycho-social risks >>study of work stations in order to prevent MSD. >>IPE committee >>salary policy Above and beyond legal and contractual provisions. In order to optimise the potential of our staff, employability is at the heart of our HR policy. On a day-to-day basis this translates into social dialogue and a strong set of values. Each person undergoes a professional interview each year and has a training plan. To this we can add a culture of safety involving significant industrial investment, promotion of safety at work, systematic analyses of the causes of accidents, implementation of prevention measures in a variety of areas (safety, maintenance training, ...). We have also developed an information system based on an internal newsletter which was set up in 2012. All of our staff (internal and part-time) receives this newsletter each month and it looks at a range of subjects affecting the company including trades, future developments, the environment and safety. This information is also disseminated over the Intranet. All staff retiring is given a reception in their honour. Receptions are held for retiring members of staff which are attended by members of the management team and their colleagues. An article is also published in the newsletter which reviews the employee’s career and their main achievements. The company attaches great importance to the wellbeing of its staff and their success. 42 | Key Indicator Key Indicators according to EMAS III Calais Absolute Database Relative* 2011 2012 2013 2011 2012 2013 [Mio €] 20.0 23.0 27.0 Total headcount [EMP] 360 404 430 Size of property [m ] 21,969 21,696 41,500 Total sealed surface [m2] 16,136 16,136 16,077 807 711 607 [m2 / Mio €] 73.0 73.0 39.0 [m3] 27,895 34,244 25,109 1,395 1,509 948 [m3 / Mio €] [kWh] 9,488,047 9,910,243 10,388,969 474,402 436,575 392,037 [kWh / Mio €] Amount of electricity from renewable energy (only external supply) [kWh] Amount of electricity generated inhouse from renewable energy 1,015,221 1,288,332 1,350,566 50,761 56,755 50,965 [kWh / Mio €] Percentage of renewable energy with regard to overall consumption [kWh] 0.00 0.00 0.00 0.00 0.00 0.00 [kWh / Mio €] [%] 11.0 13.0 13.0 [kWh] 8,664,603 9,230,912 7,412,060 433,230 406,648 279,700 [kWh / Mio €] Amount from renewable energies [kWh] 0.00 0.00 0.00 0.00 0.00 0.00 [kWh / Mio €] Percentage of renewable energies [%] 0.00 0.00 0.00 Reference data Added value in Mio. Euro General Data 2 Biodiversity Input Water Electricity ∑ Natural gas Light fuel oil [l] 0.00 0.00 0.00 0.00 0.00 0.00 [l / Mio €] Amount from renewable energies [l] 0.00 0.00 0.00 0.00 0.00 0.00 [l / Mio €] Percentage of renewable energies [%] 0.00 0.00 0.00 Fuels for internal logistics >> Diesel [l] 0.00 0.00 0.00 0.00 0.00 0.00 [l / Mio €] Amount from renewable energies [l] 0.00 0.00 0.00 0.00 0.00 0.00 [l / Mio €] Percentage of renewable energies [%] 0.00 0.00 0.00 [l] 0.00 0.00 0.00 0.00 0.00 0.00 [l / Mio €] [l] 0.00 0.00 0.00 0.00 0.00 0.00 [l / Mio €] >> Gasoline Amount from renewable energies Percentage of renewable energies [%] 0.00 0.00 0.00 [kWh] 0.00 0.00 0.00 0.00 0.00 0.00 [kWh / Mio €] Amount from renewable energies [kWh] 0.00 0.00 0.00 0.00 0.00 0.00 [kWh / Mio €] Percentage of renewable energies [%] 0.00 0.00 0.00 Propane / LPG [kg] 4,410 6,440 10,710 221 284 404 [kg / Mio €] Metanol [kg] 0.00 0.00 0.00 0.00 0.00 0.00 [kg / Mio €] District heating Energy input ∑ [kWh] 18,209,434 19,224,077 17,938,932 910,472 846,876 676,941 [kWh / Mio €] Amount of renewable energy with regard to total energy input [kWh] 1,015,221 1,288,332 1,350,566 50,761 56,755 50,965 [kWh / Mio €] Percentage of renewable energy with regard to total energy input [%] 6.00 7.00 8.00 Key Indicator | 43 Emulsion concentrates [kg] 832 208 208 42.0 9.00 8.00 [kg / Mio €] Processing oils [kg] 66,360 65,656 93,725 3,318 2,892 3,537 [kg / Mio €] [t] 5,066 4,840 5,669 253 213 214 [t / Mio €] Metal semi finished products (external supply) [kg] 779 1,831 2,269 39.0 81.0 86.0 [kg / Mio €] Other raw materials [kg] 0.00 0.00 0.00 0.00 0.00 0.00 [kg / Mio €] Metal raw materials Absolute Database Relative* 2011 2012 2013 2011 2012 2013 3,653 3,553 4,796 183 157 181 [t / Mio €] Output Waste ∑ [t] non hazardous waste ∑ [t] 114 109 228 5.70 4.80 8.61 [t / Mio €] >> paper, cardboard [t] 12.0 11.0 22.0 0.60 0.48 0.81 [t / Mio €] >> waste wood [t] 0.00 0.00 0.00 0.00 0.00 0.00 [t / Mio €] >> domestic waste [t] 102 98.0 207 5.10 4.32 7.80 [t / Mio €] [t] 0.00 0.00 0.00 0.00 0.00 0.00 [t / Mio €] [t] 501 381 1.039 25.0 17.0 39.20 [t / Mio €] >> others hazardous waste ∑ >> grinding swarf / sludge [t] 231 107 305 11.55 4.71 11.51 [t / Mio €] >> waste emulsion [t] 93.0 96.0 299 4.65 4.23 11.28 [t / Mio €] >> waste oil [t] 19.0 0.00 0.00 0.95 0.00 0.00 [t / Mio €] >> others [t] 158 178 435 7.90 7.84 16.42 [t / Mio €] Scrap (ferrous + non-ferrous) ∑ [t] 3.038 3.063 3.529 152 135 133.17 [t / Mio €] CO2-equivalents ∑ [t] 17,199 18,810 15,692 860 829 592 [t / Mio €] CO2-emissions from combustion processes at this site [t] 1,762 1,883 1,531 88.0 83.0 58.0 [t / Mio €] CO2-emissions from electricity obtained from external sources [t] 15,437 16,927 14,150 772 746 534 [t / Mio €] 1.627 1.708 1.362 [t] 0.00 0.00 0.00 0.00 0.00 0.00 [t / Mio €] CO2 - equivalent from the refrigerant agent amounts refilled due to leakages [kg] 0.00 0.00 10,872 0.00 0.00 410 [kg / Mio €] SO2 - emissions from combustion processes at the site [kg] 16.0 17.0 13.0 0.80 0.70 0.50 [kg / Mio €] NOx - emissions from combustion processes at the site [kg] 762 817 673 38.0 36.0 25.0 [kg / Mio €] Particulate matter emissons ∑ [kg] 71.0 11.0 18.0 3.55 0.49 0.67 [kg / Mio €] from combustion processes at the site [kg] 1.00 1.00 1.00 0.05 0.05 0.03 [kg / Mio €] from production an other processes [kg] 70.0 10.0 17.0 3.50 0.44 0.64 [kg / Mio €] CO2-emission factor per kWh electricity obtained from external sources CO2-emissions from district heating obtained from external sources * In relation to added value [g / kWh] 44 | Environmental Indicators Input Water Management Water usage in m3 The drinking water at the site is fed solely from the CALAIS public network. Measures are implemented on an ongoing basis to limit water requirements for the various processes. Several measures have been implemented to produce significant reductions in water requirements (through the implementation of cooling circuits for quenching oils, formalisation of quantities of water to be used for drum abrasion...) For 2013, we have differentiated the consumption for the old plant: Lafayette Boulevard and the new plant: ZAC Marcel Doret. [m3] Consumption of raw water 60,000 50,000 40,000 30,000 20,000 10,000 0,00 2008 2009 2010 2011 2012 2013 Environmental Indicators These measures have allowed us to reduce the amount of town water we use in production processes. It should be noted that over the last three years, our ratio of water consumption to manufacturing volumes has been reduced by 2/3 compared to 2008. Reducing our consumption between 2012 and 2013 is due to the introduction of a closed process of the Barillage circuit, allowing us to divide by ten our consumption. This circuit has been installed after the tranfer, in mid-2013. [m3 / VA] Consumption of water 5.00 4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0,00 2008 2009 2010 2011 2012 2013 | 45 46 | Environmental Indicators Input Energy Management Electricity consumption in kWh and details about installed capacity From 2010 to the present, our electricity consumption has remained constant, although there was a slight increase in 2012/2013 due to the arrival of new assembly machines. [kWh] Electricity consumption 10,000,000 8,000,000 6,000,000 4,000,000 2,000,000 0 2008 2009 2010 2011 2012 2013 2009 remains a special year in that we could not produce due to lack of work, but we had to keep the ovens hot. We have conducted studies in order to increase the productivity of the machines. This has significantly lowered the ratio for electricity consumption for each VA. We have also outsourced the manufacture of some components to sub-contractors. [kWh / VA] Electricity consumption 35 30 25 20 15 10 5 0 2008 2009 2010 2011 2012 2013 Renewable energy contribution in kWh Around 13% of the electricity we use comes from renewable energies. Gas in kWh This graph shows our consumption of natural gas for processes as well as the building heating system, compared to added value. Environmental Indicators 34% of our annual gas consumption is related to heating the building. The relocation of our site to the Marcel Doret urban development zone has allowed us to lower our gas consumption for heating by 50%. [kWh / VA] Gas consumption 16 14 12 10 8 6 4 2 0 2008 2009 2010 2011 2012 2013 Fuel oil in tonnes In 2012, portable heaters at the old site consumed 7 tonnes of fuel oil. This was explained by the age of the building and the heating system which, despite the high consumption of natural gas, did not provide an acceptable temperature in the production workshops. Following our relocation to the new premises, we no longer need to use portable heaters thanks to better insulation and a new heating system (gas heating). Propane in tonnes Changes in our consumption of propane are due to harsher winters in that we had to use portable heaters in some sectors to raise temperatures. End 2012, the Natural gas was replaced by propane at two oven Delemonts to improve stability within the furnace. The third oven was also changed mid 2013. [kg / VA] Conso Propane 0.50 0.40 0.30 0.20 0.10 0.00 2010 2011 2012 2013 | 47 48 | Environmental Indicators CUTTING FLUID Emulsion concentrates in kg We only use oil emulsions for our coupling rectification machines. These machines are only used occasionally depending on orders. This low usage means that we have to change the emulsion product for each production run. Oil emulsion [kg / VA] 2009 2010 2011 2012 2013 1248 L 624 L 832 L 208 L 208L Emulsion concentrates 80.00 60.00 40.00 20.00 0.00 2009 2010 2011 2012 2013 Neat oils in kg Neat oil is used to cool tools while turning, but is mainly used in component cutting. [kg / VA] Neat oils 4,000 3,000 2,000 1,000 0.00 2009 2010 2011 2012 2013 Environmental Indicators Input Metal raw materials Metal raw materials in tonnes We have conducted studies in order to increase the productivity of the machines. This has significantly lowered the ratio for electricity consumption for each production. [t / VA] Tonnage of scrap 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 0 2008 [t / VA] 2009 2010 2011 2012 2013 2009 2010 2011 2012 2013 Raw Materials 0.30 0.25 0.20 0.15 0.10 0.05 0 2008 | 49 50 | Environmental Indicators Output Waste Management Waste products Hazardous and non-hazardous waste products based on production Production of non-hazardous waste remained constant while production of hazardous waste was significantly reduced. We need to take into account the volume of parts cut and treated externally in the reduction of the waste tonnage / metre of product. The year 2013 is a special year because we have created an overproduction of waste for transfer. [t / VA] Changes in annual waste tonnage / metre product 14 12 10 8 6 4 2 0 2008 Non-hazardous waste 2009 2010 2011 2012 2013 Hazardous waste Wastage and scrap metal in tonnes We have recorded an increase in the length of chain produced while the volume of scrap metal produced has remained constant: This is due to the fact that plates and pins are made externally, but also due to the fact that our processes limit wastage. [t / VA] Wastage and scrap metal in tonnes 16 14 12 10 8 6 4 2 0 2008 2009 2010 2011 2012 2013 Environmental Indicators Output Emissions CO2-emissions associated with: Year 2011 2012 2013 8,664,603 9,230,912 7,412,060 CO2 emissions (t) associated with internal combustion processes 1,747 1,861 1,531 CO2 emissions (t) associated with electricity consumption 15,437 16,927 14,150 SO2 emissions associated with internal combustion processes 16 17 13 NOx emissions associated with internal combustion processes 761 806 673 Nat Gas (kWh) Equivalent CO2 in tonnes associated with leaks of coolant fluids R22 R134A R407C R410A 2011 0 0 0 0 2012 0 0 0 0 2013 3400 0 7472 0 The refrigerant fluid leaks are due to: >>A leak of a self piercing valve on a cooler in the tooling sector for the R22 >>A problem on an expander and a porous pipe on another cooler in sector tooling and a problem on an expander of a cooling water to the TTH, for the R407C. We involve an outside company specializing in control and repairing of our facilities. | 51 52 | Goals and Programs Environmental programmes and targets Since the launch of our environmental program we have implemented a number of environmental protection measures. We have achieved our environmental targets through the implementation of a large number of small advances. There are so many of them that we cannot list them all here. The following list only includes the most significant measures. Environmental Goals Environmental Program Reduction of waste: reduction of non-hazardous waste treatment costs >>Sorting of office paper and plastic products 100% of office paper is recovered Relocation >>Application for a classified installation for the new site Creation of the request for operational authorisation Reduction of consumption >>Reduction of compressed air leaks Fitting of electrovalves on assembly lines Goal has been achieved. Achieved? Actions Part of goal has been achieved. Additional actions planned. Goal not achieved. Other actions not included in the program Environmental Goals Environmental Program Prevention for working conditions >>Establishment of a new noise map Prevention of emergency situations >>Purchase of a portable gas detector for access to cellars >>Training of new hirings Goal has been achieved. Achieved? Actions Study performed with the occupational physician on measures to be maintained at the new site Implementation of a general training system for all new hirings Part of goal has been achieved. Additional actions planned. Goal not achieved. Goals and Programs | 53 Improvements not included in annual target planning Only specific and realistic targets can provide long-term environmental protection. Environmental programs must include applicable measures. Here we have only listed the main environmental targets of the program over the last three years. Supervisors have been appointed to make sure all measures are correctly implemented. Environmental Goals Environmental Program Responsible Complete by Reduction of water consumption to a third >>New water treatment system for the drum abrasion sector Components 2013 50% reduction in gas consumption for heating >>Better insulation for buildings >>Recovery of energy from compressors Purchases Maintenance 2013 2014 5% reduction in the consumption of electricity >>Use of low-energy lighting equipment Purchases 2013 Reducing environmental damage >>No discharge into drains >>Construction of a waste product centre >>Construction of water storage tanks Safety Safety Safety 2013 2014 2014 Reduced waste production (decrease by 50% the volume of saline water to destroy >>Purchase of a desalinator Components 2015 Reduced consumption of compressed air (-20%) >>Execution of the campaign Maintenance 2013 Prevention of soil pollution >>Sealing of floors and walls of pits using heat treatment Components 2013 Air cleanliness >>Installation of new equipment to meet standards in force at the new site Safety 2013 Prevention of emergency situations >>Installation of smoke vents >>Installation of RIAs Safety Safety 2013 2013 54 | Validation Validation and responsibilities Validation The undersigned, Dr. Ing. Norbert Hiller, EMAS Environmental Verifier, Registration Number DE-V-0021, accredited or authorized for the area designated by NACE code 29.32, confirms that his inspection of the location at „1000 rue Louis Breguet“ „62100 CALAIS“ has determined that „SCHAEFFLER CHAIN DRIVE SYSTEMS“ registration number DE-158-00016 as indicated in its environmental statement, complies with all requirements stipulated by (EU) Directive No. 1221/2009 by the European Parliament and Council dated November 25, 2009 on the voluntary participation of organizations in a joint system for environmental management and eco-audits (EMAS). The signatures at the end of this statement confirm that >>the inspection and validation have been completed in full agreement with the requirements stipulated in (EU) Directive No. 1221 / 2009 >>the result of the inspection and validation confirms that no evidence of non-compliance with valid environmental specifications has been found >>the data and information in the environmental statement for the location at „1000 rue Louis Breguet“ „62100 CALAIS“ as part of „SCHAEFFLER CHAIN DRIVE SYSTEMS“ represent a reliable, credible and true picture of all activities at this location within the area indicated in the environmental statement. Validation This statement cannot be equated to EMAS registration. EMAS registration can be complated by an authorized agency in accordance with (EU) Directive No. 1221 /2009. This statement must not be used as an independent basis for informing the public Done at Calais, on 29. January 2014 Dr. Ing. Norbert Hiller Environmental Verifier Responsible for environmental protection and occupational safety at the SCHAEFFLER CHAIN DRIVE SYSTEMS location: S. Brebion Environmental Supervisor Responsible for the environmental statement at the SCHAEFFLER CHAIN DRIVE SYSTEMS location: JF. Masbou Director of the site The next consolidated environmental declaration will be published in December 2016. A simplified declaration is published each year. | 55 3.000 Stück 3.000 Stück 3.000 Stück 1.000 Stück Ordnerform Ordnerform März 1998; Mai 1999; Juni 2003; Januar 2006; Oktober 2007; Mai 2008; Gesamtherstellung: 6. aktualisierte Auflage 1. Auflage; 2. Auflage; 3. Auflage; 4. Auflage; 5. Auflage; 6. Auflage; Bisher erschienene Auflagen: Auflage: 6. aktualisierte Auflage Auflage: Dr. Rainer Sieg, Jelena Maric Autoren: Dr. Rainer Sieg, Jelena Maric Autoren: From other countries: Phone +33 321 466848 Fax +33 321 961910 Herausgeber: France: Phone 0321 466848 Fax 0321 961910 Impressum: Internetwww.schaeffler.fr E-Mail [email protected] Siemens AG KSpA-/GSpA-Büro, Erlangen S. Brebion 1000 rue Louis Breguet 62100 Calais Herausgeber: Siemens AG KSpA-/GSpA-Büro, Erlangen Questions about environmental Protection at the location: SCHAEFFLER CHAIN DRIVE SYSTEMS Questions about environmental protection and safety at Schaeffler: Internetwww.schaeffler.com E-Mail [email protected] Germany: Phone 09132 822058 Fax 09132 82452058 Design and Print: 1. Auflage; 2. Auflage; 3. Auflage; 4. Auflage; 5. Auflage; 6. Auflage; Gesamtherstellung: © Schaeffler Technologies AG & Co. KG · 2014, July This publication or parts thereof may not be reproduced without our permission. Impressum: Moreover, the report contains information about issues pertaining to occupational safety, plant security and fire protection as well as general information on social benefits provided by the company and this location. Bisher erschienene Auflagen: The structure and contents of this report correspond to the requirements stated in Annex IV of Regulation (EC) No. 1221 / 2009 of the European Parliament and the Council dated November 25, 2009 regarding the voluntary participation of organizations in the eco-management and audit scheme (EMAS). März 1998; Mai 1999; Juni 2003; Januar 2006; Oktober 2007; Mai 2008; 3.000 Stück 3.000 Stück 3.000 Stück 1.000 Stück Ordnerform Ordnerform From other countries: Phone +49 9132 822058 Fax +49 9132 82452058 Tel. +49 (0) 9131/490732, [email protected] Norbert Hörauf Industriestraße 1-3 91074 Herzogenaurach