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FPT Industrial & Sustainability
Transcript of FPT Industrial & Sustainability
FPT Industrial certifications:
Environment: ISO 14001 for all our plants
Health & Safety: OHSAS 18001 for all our plants
Energy: ISO 50001 for our European plants
FPT Industrial plants adopt the World Class Manufacturing Program.
2011 Environmental responsibility main results:
-49 % over 2009 in water consumption per production unit
-28% over 2009 in average CO2 emission per production unit Sustainability As part of Fiat Industrial group, FPT Industrial adhere to the Environmental Guidelines, a document outlining commitments that uphold environmental protection and providing indications on how new products are to be developed, manufacturing activities managed and objectives reached. The scope of application of the Environmental Guidelines encompasses all stages of the product life cycle – from design to manufacture and from use all the way up through the end of the life cycle. Among the approaches listed, particular emphasis is given to reduction in the use of energy, raw materials, hazardous substances and polluting emissions, as well as to responsible water management, limitation of waste generation and conservation of natural habitats and biodiversity FPT Industrial products of tomorrow are developed in FPT Motorenforschung, our Research and Development Center in Arbon (Switzerland). Employing two hundred expert researchers, it was here that solutions were tested, enabling FPT Industrial engines to reduce their emissions and become Euro VI and Tier 4B compliant ahead of the regulatory standards.
FPT Industrial engines are tested in Arbon with a view to maximizing engine power density, duration and reliability while minimizing consumption. The Center is equipped with state-of-the-art facilities for visual testing, physical testing and simulations. Virtual testing in Arbon means that new engines can be developed in less than 36 months. The Center also has a department dedicated to road testing vehicles.
For diesel engines, new solutions are tested to improve engine efficiency, with the goal of constantly reducing consumption and emissions. Another area of focus is the study of second generation biodiesel, a high quality synthetic fuel by far superior to ordinary diesel. Second generation biodiesel can be converted from certain types of plants but also from biomass, bringing the added benefit of recycling waste. THE TRUE VALUE OF A MULTINATIONAL SUCH AS FIAT INDUSTRIAL IS ALSO DETERMINED BY HOW IT CONDUCTS ITS ACTIVITIES, BY ITS CONTRIBUTION TO IMPROVING THE PRESENT AND BUILDING THE FUTURE, BY ITS COMMITMENT TO SOCIETY AS A WHOLE. Sergio Marchionne
Chairman Download FIAT Industrial
Sustainability Report 2011 http://www.fiatindustrial.com/en-US/sustainability/FiatDocuments/FI_ENG_SOSTENIBILITA_indicizLOW.pdf For the Euro IV/V emission standard introduced in 2005, FPT Industrial chose the SCR path, a choice that was made purely from a cost of ownership point of view, allowing the engines to be tuned to fully optimise combustion efficiency, and hence fuel efficiency, at the expense of high engine-out NOx emissions that could be reduced by the SCR exhaust after-treatment.
For Euro VI, neither FPT Industrial’s strategy nor our customers demand for fuel efficient vehicles has changed. FPT Industrial is able to exploit the technological strides taken in its continuous developments to further improve the efficiency of the SCR technology. This has led to a fully patented SCR control system that allows unprecedented reduction efficiencies to be achieved. This cutting-edge technology patent allows a massive reduction of emissions according to the Tier 4 Final and Euro VI, with the conversion level of NOx notably high. Alternative fuels CNG and hydromethane CNG (Compressed Natural Gas) is at present the truly alternative fuel to diesel, as well as the cleanest among the ones available in the market. CNG assures a notable reduction of CO2 and harmful emissions (PM, aromatic compounds such as benzene).
It can be carried through pipelines e not with tankers (therefore less traffic on the surface, less pollution and more safety) and unlike oil, has a broad geographical distribution.
The technologies developed for natural gas are the ideal starting platform for a gradual use of hydrogen in vehicles.
With little actions on the software of the engine electronic control, CNG engines can be powered by hydromethane, a mixture of methane and hydrogen in a ratio of no more than 70/30 (in volume), that achieves a reduction of CO2 emissions by up to 11% compared to a vehicle powered only by natural gas. BiFuel Ethanol-Diesel FPT Industrial presented the new BiFuel Ethanol-Diesel Cursor 9 engine that can run on an ethanol and diesel mixture with lower fuel costs when compared to a conventional diesel engine.
Designed to be used by sugar-cane and ethanol producers on their specific agricultural and industrial operations, the engine has been using a 40-60% ethanol-diesel average fuel mix on early tests, which contributes to reduce fossil fuel use and allows for an improved environmental proposition, since ethanol is a fully renewable fuel.
Ethanol is injected directly into the intake manifold during the admission stage. After the compression stage, diesel is injected to promote combustion.
This project has been developed in Brazil with the support of sugar-cane producers under a program to promote green policies in the sugar and ethanol business. Hybrid tractions FPT Industrial has been active for years in the field of alternative traction.
FPT Industrial customers’ vehicles use the Parallel Hybrid Architecture, ideal for large urban areas. The internal combustion engine and the electric one can act in a coordinated manner, or one without the other, depending on the vehicle mission profile. Smartly exploiting the qualities of both electric and diesel engines, the hybrid vehicle reduces fuel consumption and emissions. During deceleration, the electric motor works as a generator, converting kinetic energy into power that is stored in batteries, instead of being scattered and wasted.
In this way it is possible to save fuel up to 30% in urban areas, with a corresponding reduction of CO2 emissions. + 16.000 engines!!! Remanufacturing
Remanufacturing of certain parts and components is a strategy for prolonging the life of vehicles. By reconditioning and readapting parts, remanufacturing extends the component life cycle.
At its Garchizy plant in France, FPT Industrial remanufactures engines and parts, bringing them back to their initial state and giving them a second life. The plant only remanufactures engines and parts sourced from authorized Iveco and CNH dealers. Remanufacturing processes are performed in accordance with ISO 9001/2000 and ISO 14001 standards, thus assuring the flawless quality of the final product. R & D Arbon (Switzerland) Environment Health and Safety Management Energy Management WCM The effective implementation of a policy centered around environmental protection is ensured through an Environment, Health and Safety (EHS) unit, which is responsible for dealing with environmental issues and other issues related to occupational health and safety. The purpose of these structures is to operate so that the targets of individual sectors are implemented locally, at each single plant, ensuring uniformity and seamless compatibility with the specific aspects of the different businesses.
Our plants within the FPT Industrial Environmental Management System are in conformance with the ISO 14001 standard.
Within Fiat Industrial 2010–2014 Environmental Plan aimed at reducing the impact of manufacturing processes, FPT industrial pursues the objective of reducing its environmental footprint, in all of its manufacturing processes as:
Atmospheric emissions monitoring of Volatile Organic Compounds (VOC), Ozone Depleting Substances (ODS), Nitrogen oxides (NOx), sulfur oxides (SOx) and dust
Waste management Atmospheric Emissions Waste VOC
Of all manufacturing processes, painting has the greatest environmental impact. As a consequence, Volatile Organic Compounds (VOC) emissions due to this process are monitored within the environmental plan with specific target reduction. Water VOC
Water management includes:
Analysis of water requirement and consumption with plant rules and management for withdrawal and distribution
Definition of interventions on water resources that boost efficiency
Water recycling and reuse
Elimination of leaks and waste of materials
Raising the awareness of all personnel on careful use of the resource All plants operate based on constant improvement of their processes in order to reduce the amount of waste generated and to manage it from the standpoint of recovery and reuse.
The principles governing waste management are:
Reduction of the amount of waste generated and of its hazardousness
Enhancement of separate waste collection
Initiation of disposal – should recovery/reuse not be an option
Training and awareness programs on procedures for daily waste management Our Energy Management System and certification procedure are compliance with the ISO 50001 international standard.
The standard proposes an energy management system that enables the development and implementation of an energy policy, objectives and action plans covering legal prescriptions and information on significant energy consumption.
The advantages deriving from ISO 50001 certification mainly consist in exploitation of a systematic approach to constant improvement of energy performance, resulting in a more efficient and rational use of energy, thus capable of bringing not only the expected financial gain but also a reduction of greenhouse gas emissions.
Some of principal operations for managing energy consumption and increasing efficient use of equipment are:
High-efficiency lighting systems (LED, T5 fluorescent lights or dimmers) for production facilities, offices and external areas, combined with light intensity regulators and motion sensors
High-efficiency engines, electric motor inverters and variable speed air compressors
Intelligent stand-by equipment on machining centers and transfer lines
Management of space heating in the workshops through precise analyses of consumption and temperature.
FPT Industrial overall annual energy consumption performance was -24% for the light duty engines and transmissions division and -17% for the heavy duty engine division, over the 2009 baseline. World Class Manufacturing activities being developed inside our plants are periodically assessed by qualified auditors.
Both technical and management pillars are evaluated with a score included within a range between zero and five points. The overall plant score is calculated as the sum of the scores of the twenty pillars. Mobility management Green ICT During 2011 FPT Industrial has developed a mobility management project including:
Public transport: reorganization of special lines, intensification and reallocation of scheduled services during specific time slots, introduction of new shuttle services prior to and following shifts
Car pooling: establishment of a web platform that enables employees to find co-workers interested in car pooling to and from work
Easy cycling: installation of new parking spaces for bicycles and improvements to cycle paths in and around the complex. Within Fiat Industrial, Green ICT plan aimed at reducing energy consumption and associated CO2 emissions. FPT Industrial joined the program to replace hardware with equipment with more efficient power supply systems and monitors with new EnergyStar and EPEAT Silver/Gold rated units. Logistic Primary targets in this area relate to cutting CO2 emissions associated with the handling of components and finished goods and minimizing the use of non-reusable packaging.
The chosen approach is based on four paths of action:
Increase in low-emission transport
Use of intermodal solutions
Optimization of transport capacity
Reduced use of packaging and protective materials to gradually replace disposable cardboard packaging with reusable containers
The Green Logistics Principles complete the World Class Logistics standards, which are based on the World Class Manufacturing program, meant to define integrated logistics processes at plants as well as in planning for the supplier network, to meet the requirements of safety, ergonomics, eco-compatibility and transport flow optimization.
Streamlined Delivery is a projects aimed to optimize transport capacity to reduce both costs and environmental footprint: it consists in outsourcing the organization of the collection of material destined to manufacturing sites to a pool of logistics providers, in place of delivery through transportation by individual suppliers. The Power of Sustainable Thinking