TOYOTA MATERIAL HANDLING EUROPE 1
TOYOTA MATERIAL HANDLING EUROPE
ISO 50001
LTE Spa – Toyota Material Handling
TOYOTA MATERIAL HANDLING EUROPE 2
Team knowledge sharing
Reducing energy
consumption through
the implementation of
ISO 50001 May 2015
TOYOTA MATERIAL HANDLING EUROPE 3
SUSTAINABILITY STRATEGY SUPPORTS BUSINESS STRATEGY
SET INDUSTRY STANDARDS
SUSTAINABLE COST SAVINGS
COMPLIANCE
REVENUES▲
NEW PRODUCTS
= Action required
= Opportunity for improvement
= On the right track
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Where are we today?
SUSTAINABLE COST SAVINGS
SUSTAINABILITY STRATEGY SUPPORTS BUSINESS STRATEGY
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Example of 1 new directive with
Significant impact on our business
• Ensuring compliance with new Energy Efficiency directive
covering buildings, vans and cars
• Identifying EU wide opportunities for sustainable cost saving
• Auditors will also investigate our in house forklift fleet which will
better prepare us to respond to customer queries as they have
the same audit obligations
SUSTAINABILITY STRATEGY SUPPORTS BUSINESS STRATEGY
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Why ISO 50001?
2015
2020 2030
Si prevede una
crescita della
domanda di energia
primaria del 45%
(al 2030) equivalente a
+1,6% medio annuo.
SUSTAINABLE COST SAVINGS : Establishing a model to predict future energy costs – first draft, gaps to be filled after energy audits
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Self-Introduction #3 GMM Self-Introduction #3 GMM 4. Raymondの活動 Group Discussion ISO 50001 MEMBERS Factory; LTE
Location Photos
Production Items Outline of a Factory
Ferrara, Italy
Factory
Standard & Special
Mast Fork Positioner Integrated
Sideshifter
Address Via Caravaggio, 6
44020 S. Giovanni di Ostellato(FE) - Italy
1976
Site area 60,000 m2
Building area 14,000 m2
Employees 360
Main products Develop and Manufacture mast & equipment
Volume of factory shipments
(FYE2013) 16116 (FY2015)
Start of operations
(as of January 31, 2015)
Person in Charge
Marsan Costanzo ASGE
Zaramella Rudy RSGE
Team Member
Ferroni Fabrizio GL Maintenance
Ferrari Andrea PE
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What is ISO 50001?
10
ISO 50001 is an international
standard aimed implementing an
energy management system that
adopts the Deming cycle PDCA
(Plan - Do - Check - Act) in order to
achieve continuous improvement
in the energy management .
ISO 50001 represents a further
element of the integrated
management system that includes the
issues of quality, safety and
environment. The standard does not
define specific performance criteria
relating to energy but helps
companies to organize systems and
processes aimed to energy efficiency
improvements: a management that
leads to the reduction of energy
consumption resulting in both
economic and environmental benefits.
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• Focus on the performance of the organizations
• Deep analysis of all the process
• Improvement in processes in terms of energy efficiency
• Structured pay-back system based on PDCA improvement
• Accordance with local laws ( DLgs 102/2014 )
Why did you decide to implement ISO 50001?
EFFICIENCY IN PROCESS
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How long / complicated was to implement ISO 50001?
• To implement such
management system depends
strongly on the complexity of
the system analyzed.
• Energy audit and machinery
census is the most challenging
part.
• Consumption monitoring plan
as a result of energy balance.
• Documentation and
sensibilization to all
employees.
• Time estimation to achieve
certification: from 4 to 6
months.
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1
Below we present some basic steps that a company realize for the energy management
system implementation and ISO 50001 certification:
2
Definition of energy policy: preparation documentation similarly to other
management systems (ISO 9001;ISO 14001; ISO 18001 )
1. Census of all the equipment
2. Historical analysis of consumption by:
• analysis of the energy meters and analyzes production
data;
• identification of energy performance indicators (E-KPI);
• economic analysis
3 Baseline and target set-up
1
2
3
How long / complicated was to implement ISO 50001?
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Helping to achieve energy use reduction and carbon emission in a systematic way
Creating a clear picture of current energy use status, based on which new goals and targets can be set
Evaluating and prioritizing the implementation of new energy-efficient technologies and measures
Providing a framework to promote energy efficiency throughout supply chain
What have been the benefits of the implementation and what could be the
benefits for other factories?
Providing guidance on how to benchmark,
measure, document and report corporate energy
use
Making better use of energy consuming assets,
thus identifying potentials to reduce
maintenance costs or expand capacity
Demonstrating to the stakeholders that
corporate commitment to comply with their best
practice to protect the environment
Fulfilling the associated regulatory requirements
and responding with confidence to green trade
barriers in global market
TOYOTA
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Some examples of improvements achived
Item
ENERG
Y
ASPECT
DEP. OBJECTIVE Ref. PDCA TARGET EnPI ACTION/S STAT
US
4 Lighting Milling
Saving in cost
of eletrical
energy
Countermeas
ure sheet
Energy
saving
10666
Saving
(kWh /
year)
Replacing the
transparent
cover increase
natural lighting
Done
6 Electric
motors All
Increase the
efficiency of
the motors in
the machines
more than 10
years aged
Countermeas
ure sheet
Energy
saving
We made a summary
report were evaluated n.
18 electric motors (total
installed capacity 312.2
kW) with portable
analyzer and was
estimated potential
economic savings of 14
353 euro.
Perform
efficiency tests
of the motors
during working
time
Done
15 Lighting FCA
Reduce
Eletrical
consumption
Countermeas
ure sheet
Ligting saving
2540
Saving
(kWh /
year)
Replacing neon
lamps (36W)
with LED lamps
(20W);number
of lamps 32
Done
23
Gas
consump
tion
reductio
n
Coatin
g Plant
Reduce gas
consumption
Countermeas
ure sheet
Energy
saving
3 (saving)
m3 /h
Use low curing
temperature
paints
Done
4
ACTIVITIES FOR IMPROVEMENTS
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1. Energy Management system
Just-in-time monitoring energy system
What you have planned to do regarding your energy management?
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2. Energy cost saving for plant lighting
Actual System
Absorption per user = 450 W
Industrial luminaries
Absorption per user = 205 W
An example of saving:
replacement of old lamps with new LED Smart lamps
What you have planned to do regarding your energy management?
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Lighting
system
cost
monthly cost
(*)
Annual
energy
Saving
Cost
saving
(5 years)
Net
income
(5 years)
Annual
envir.
saving
(ton CO2
eq.)
Annual
envir.
saving
(TEP)
€ 117.300 € 1.995 MWh
155,144 € 139.027 € 19.320 62 29
In the following table we summarize the energy, economic and
environmental results related to the project provided
(*) 60 installments
2. Energy cost saving for plant lighting
What you have planned to do regarding your energy management?