GB

FAQ Frequently Asked Questions Approach to sustainability

12/2012 2/17

Content Sites in Austria.........................................................................................................................................................3

Economic situation – Product liability – Credit status .............................................................................................3

Production ...............................................................................................................................................................3

Product range ......................................................................................................................................................3

Production systems and equipment.....................................................................................................................3

Materials, bought-in parts ....................................................................................................................................3

Manufacturing process ........................................................................................................................................4

Production areas ..................................................................................................................................................4

ENERGY AND RAW MATERIALS REQUIREMENTS FOR PRODUCTION ......................................................6

Procurement – Material inspection – Storage .........................................................................................................8

Quality system ...................................................................................................................................................... 11

TESTS .............................................................................................................................................................. 11

Incoming goods inspection ................................................................................................... 12

Intermediate inspection ........................................................................................................ 12

Final inspection .................................................................................................................... 12

TEST EQUIPMENT ............................................................................................................. 13

TEST STATUS .................................................................................................................... 13

MANAGING FAULTY PRODUCTS .................................................................................................................. 14

CORRECTIVE MEASURES ............................................................................................................................. 14

QUALITY RECORDS ....................................................................................................................................... 14

Health, Safety and the Environment .................................................................................................................... 15

© Fronius International GmbH

Version 1.0 12/2012

Facility Safety – Herwig Flatscher

12/2012 3/17

SITES IN AUSTRIA Pettenbach Sattledt Steinhaus Thalheim Wels

ECONOMIC SITUATION – PRODUCT LIABILITY – CREDIT STATUS As a matter of principle this information is not disclosed. If you have any questions or require more information please contact environment@fronius.com.

PRODUCTION

Product range

The company is made up of three divisions:

Battery Charging Systems: Battery chargers for starter batteries and traction batteries, based on Ac-

tive Inverter Technology

Welding Technology: from electrode welding devices, TIG power sources and MIG welding systems

through to complex automation solutions and new technologies such as resistance spot welding (Del-

taSpot)

Solar Electronics: Development and production of grid connected photovoltaic inverters and compo-

nents for professional system monitoring

Production systems and equipment

As a matter of principle this information is not disclosed. If you have any questions or require more information please contact environment@fronius.com.

Materials, bought-in parts

As a matter of principle this information is not disclosed. If you have any questions or require more information please contact environment@fronius.com.

12/2012 4/17

Manufacturing process

Fronius International GmbH has various manufacturing areas. These include:

Mechanical

Electronic

Assembly

A variety of different methods are used in each of these manufacturing areas.

Production areas

Available Premises Comments

Yes No Separate Integrated

Goods in / Warehouse ☒ ☒

Weld shop Ferrite ☒ ☒

Weld shop Austenite ☒ ☒

Storage of filler materials ☒ ☒

Baking oven for electrodes

☒

Electrode welding is only per-formed during the final exam for apprentices.

Mechanical engineering work-shops

☒ ☒

Assembly ☒ ☒

Dipping, sand blasting, finishing ☒

☒

☒

☒

Degreasing and passivation + finish = powder coating

Finished products store ☒ ☒

Quarantine area ☒ ☒

Measurement and test areas ☒ ☒ ☒ Air-conditioned

Test laboratory ☒ ☒ ☒

Packaging ☒ ☒

Despatch ☒ ☒

Clean room

☒ ☒ Currently under evaluation; a pilot will be installed for testing purpos-es within a few weeks

Do written instructions for manufacturing processes exist? If so, what are they? yes x no

Work instructions, test schedules, safety instructions, documented procedures

Do production schedules that specify the key parameters exist? yes x no

Work instructions (process-specific) and test schedules, production documentation (product-specific)

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Are procedures, processes and production equipment tested for suitability

and approved? yes x no

With new plants the specified parameters are tested and approved by process engineering.

Sometimes external institutes are also involved.

Solder analyses are checked externally

Testing equipment is periodically inspected and approved by an external body using calibration and measuring equipment.

The datalogger is used to record and check process-specific data every 3 months.

An internal process is employed to approve and test production equipment in terms of its ergonomics and safe-ty.

Machine acceptance is carried out prior to purchase.

The quality management system ensures that procedural and process investigations are carried out.

Machine capability investigations

Procedural investigations

Sample approval before series production

Are suitably qualified personnel used? yes x no

Yes, this is ensured by the job advertisements and the employee qualifications matrix. Are up-to-date instructions available at the workplaces for

Production? yes x no

Work instructions (process-specific) Sample PC boards Work instructions The latest version of the drawing is provided with each order.

Installation? yes x no

Work instructions

Testing? yes x no

Test schedules

Are the work steps and test steps that are carried out documented? yes x no

Some of the work steps are initialled on the working papers. Test steps are saved according to serial number using the FTS database. Test steps are recorded digitally using the automatic test equipment. Manual tests are currently documented during the internal rework process. In the case of nonconforming parts, rejection is logged directly. Measurement data is not documented.

Is a process controlled on the basis of the measured data? yes x no

This is under development (FTS) and is already carried out on pilot processes (casting line). Control circuits are installed almost universally in every automated system.

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The process is corrected with the help of the results measured according to the test schedule. For special procedures

Are processes qualified? yes x no

Process qualification is carried out for new processes/systems.

Are process parameters specified in writing? yes x no

Process parameters are provided by R&D in the "Technical Manual". The process parameters for the electronic system are obtained from the IPC610D. An NC program, maintenance schedules and equipment schedules are provided.

Are process parameters monitored? yes x no

They vary according to the process (screwing processes: see screwdriver classification, casting line, etc.) Automated monitoring is performed using the integrated control circuits. Are the production and testing facilities

large enough? yes x no

well lit? yes x no

Yes, checked by Facility Safety

clean and tidy? yes x no

Yes, also checked by 5S audits.

Are machines, equipment and tools clean and well maintained? yes x no

Ensured through 5S, total productive maintenance

Is the production equipment maintained? yes x no

Yes, there is a dedicated team for this purpose. Dedicated maintenance and service schedules for the systems are also available.

ENERGY AND RAW MATERIALS REQUIREMENTS FOR PRODUCTION

Have measures been taken during production to reduce the energy consumed while manufacturing the product, or are such measures planned? Explain them using key words and include their effect in terms of savings (e.g. change to a process, process optimisation, insulation, renewable energy sources, etc.).

e.g.: utilising the ice formation effect of the nitrogen evaporator. This is used for cooling water for the systems.

Wherever possible, potentials for optimisation are acted upon.

The energy efficiency of new machines is monitored very closely.

Energy recovery when carrying out final inspections on power sources and solar inverters. Electric screwdrivers are used as they are more energy-efficient than pneumatic screwdrivers.

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Are particular efforts made to reduce the amount of raw material required to produce the products? If so, please describe using key words the measures taken and their effect in terms of savings (e.g. opti-mising cutting to size, reducing/recycling waste, effective saving per product [g, kg, %], etc.).

"Electronic waste" is recycled separately (solder dross, components, etc.).

Where possible, faulty modules and end devices are repaired.

Special programs that ensure the most efficient layout of production parts on a sheet, thereby minimising cut-off scrap.

"Mechanical waste" is recycled separately.

Recycled powder is used in powder coating.

Are provisions in place for dealing with faulty products? yes x no

Rework process, rework stations and the process instruction. Miscellaneous:

Use of resources – Conservation of resources Using resources sparingly is one of the guiding principles at Fronius and is enshrined in the Fronius Way II.

Energy saving potentials – Energy saving measures Last User rule = the last employee switches off the entire power circuit in a defined area CIP (Continuous Improvement Process) is the process by which employees identify and harness potentials. Depending on the level of utilisation, machine capacities are harnessed in a manner that conserves resources as far as possible.

Measures to increase employee satisfaction CIP = employees become more actively involved Job rotation = employees work on a number of different workstations Employee socials and trips, opportunities for further development, employee reviews

Measures for stabilising manufacturing quality

Ongoing product and process audits

Employee qualifications matrix

Further education and training opportunities

New technologies

Process monitoring

Poka-yoke training

Continuous monitoring of important KPIs

.

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Are incoming goods, intermediate and final inspections

performed and documented systematically? yes x no

Yes, by means of FTS (100% testing) or preliminary testing of modules, individual components.

Yes, tests performed between the processes and a 100% final test include AOI, MOI, FTS, Flying Probe and MTS (manual test system).

Yes, performed in accordance with test schedule. However, not documented. Actions are initiated immediately in the event of a failed test.

PROCUREMENT – MATERIAL INSPECTION – STORAGE

General warehouse logistics

Our job is to ensure integrated control of the flow of goods and the associated flow of information, from goods receipt to delivery of goods to the customer. This involves the handling, control and optimisation of the flow of goods and information, as well as storage and supply for production. The ongoing development and optimisation of process speed and process quality is our goal.

Special storage

Flammable and hazardous materials are kept in appropriate storage areas. The Warehouse Man-agement System ensures the appropriate level of control for this purpose.

Incoming goods inspection

Our supplier management system ensures that our components are of the highest quality. Critical components are additionally subject to a special incoming goods inspection. This is managed by our ERP system, carried out using the test schedules stored in it, and also documented in that sys-tem.

Goods labelling and identification

Consistent labelling of goods throughout our supply chain ensures that our components and prod-ucts can be identified at any point. Technical specifications for components are documented in a components database. In addition, requisite control measures (e.g. FIFO (first in, first out) as well as traceability for com-ponents and products are supported by our Warehouse Management System.

Defective goods or goods that fail to meet the required quality standard are labelled separately and temporarily stored in a quarantine area.

Employee qualifications / process quality

The ongoing development and optimisation of process speed and process quality is our goal.

Every employee who joins the company (Warehouse Logistics) undergoes a training programme that is tailored to the work they will be doing. Evidence of employee qualification is represented in a Q matrix.

Work instructions safeguard the process reliability and quality of our work.

Our QM department performs regular audits to ensure that our processes are adhered to and are sustainable.

12/2012 9/17

When material is delivered, is it checked against

the order? yes x no

the delivery note? yes x no

quality certification/documentation? yes x no

Are non-identifiable or faulty materials/goods

stored separately? yes x no

Are supplied materials/goods labelled and/or stored separately? yes x no

Is there any equipment with particular storage requirements,

e.g. for filler metals? yes x no

Are safeguards in place to prevent any confusion between products and

technical documents at any point between receipt and delivery yes x no

Is there an end identifier to ensure that products and

individual components can be identified in the utilisation phase? yes x no

Are products identified

by an accompanying document? yes x no

by identification of the components themselves? yes x no

by tags? yes x no

When moving towards decisions about issues such as investments, servicing,

use of consumables, etc., do you evaluate and take into account the environ-

mental impact that these decisions can have? yes x no

Note: For major investments a cost-effectiveness analysis must be carried out, and this includes the above issues. For repeat orders these issues are also considered (container management, reusable packaging, etc.). Use of consumables is checked by the relevant technician. Servicing should preferably be carried out by companies based locally. Do you have a system for selecting and evaluating your suppliers?

yes x no Note: All suppliers are reviewed on an annual basis by our supplier assessment. Our SCM strategy specifies that one of the factors we must consider when selecting a supplier is the environ-mental perspective. This is managed in the supplier evaluation process and/or the audit process.

12/2012 10/17

Is there a list of accredited suppliers who comply with ISO 9001 ff.? partially Note: All approved suppliers are documented in a list. We cannot be 100% certain that all our suppliers are ISO-certified. Are suppliers regularly checked / audited, and are reports compiled on the process? yes x no

Note: The supplier audit process is documented in the SCM strategy. Are orders checked against the following criteria before approval?:

Commercial yes x no

Technical yes x no

Quality requirements yes x no

Customer requirements yes x no

Quality certification/documentation yes x no

Note: All orders to our suppliers are processed in accordance with the defined procedures, and all the points listed above are followed.

Are any materials from the REACH list of "materials that are cause for particular concern" used in the manufacture of main components / raw materials and finished products? If so, are measures being / have measures been taken to improve the situation? If the answer to the above question is not known, will you obtain the relevant information from the manufacturers? No, we do not use such materials.

Do you conduct development activities in-house? yes x no

Are development activities outsourced to third parties? yes x no

Materials labora-tory:

inter-nal

exter-nal

Chemical analysis

Hardness test

Metallography

Tensile test

Warm tensile test (temperature measurement and control equipment)

Notched bar impact test min. temp. ______ °C

Pressure testing with Air Water Oil Vacuum

Leak testing with Air Helium Vacuum Water bath

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QUALITY SYSTEM

We constantly ensure that the quality of our products and services is in line with the demands placed on us.

Quality is at the heart of everything that every department of the company does. Quality awareness is a key Fronius value that is instilled in all employees, safeguarding the quality of products and processes alike.

Fronius has been certified since 1993 and is continuing to drive forward its documented quality management system in line with ISO9001 requirements.

The development process used for implementation of pre-development, product range and adaptation projects is based on a phase model with clearly defined quality gates that cover all stages from the order to provide a specification through to the ramping up of production.

Incoming goods inspections on bought-in parts are performed in accordance with variable random sample in-structions according to the number of OK deliveries or ongoing 100% testing in the case of safety-critical com-ponents.

Incoming goods, intermediate and final inspections are carried out by trained personnel using calibrated meas-uring and testing equipment.

All finished products are subject to a 100% final inspection before delivery to the customer.

Fronius uses supplier, system, process and product audits as proof of compliance with the stipulated require-ments. The selection and qualification of suppliers is carried out in the context of supplier audits based on standardised audit checklists and assessment criteria. Random product audits are carried out during the manu-facturing process.

A regular assessment of our quality management system is carried out by an external certification company or during customer audits.

Is the company or the site certified to ISO 9001:2008? yes x no

Does the company have a Quality Manual? yes x no

Are internal audits carried out at scheduled intervals? yes x no Is there an audit schedule in place?

Are actions agreed upon as a result of audits? (see ..... for additional questions) yes x no

Is the management team informed of this? yes x no

TESTS

With regard to all tests Is responsibility for test scheduling assigned for the

incoming goods inspection? yes x no

intermediate inspection? yes x no

final inspection? yes x no

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Does the test documentation include the necessary data, e.g. nature and scope

of tests? yes x no

Are the testers suitably trained? yes x no

Are test documents kept at the workplace? yes x no Are the test results

recorded? yes x no

evaluated (statistics)? yes x no

retained (how long)? yes x no

Incoming goods inspection

Does an incoming goods inspection take place?

Number/quantity yes x no

Identification yes x no

Do the delivery documents, the goods and the order documents all agree? yes x no

Visual checks yes x no

Dimensional checks yes x no

Other tests yes x no

If the goods are faulty, are the purchasing and scheduling departments noti-

fied? yes x no

Intermediate inspection

Are intermediate inspections carried out? yes x no If so, are they conducted as

self-tests? yes x no

tests by quality testers? yes x no

Final inspection

Is a check for completeness carried out/ have previous inspections been con-

cluded satisfactorily? yes x no

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TEST EQUIPMENT

Has all quality-related test equipment been logged? yes x no Does the test equipment file / index card include

identification number? yes x no

manufacturer, type, application? yes x no

commissioning date? yes x no

monitoring interval? yes x no

date of inspection? yes x no

findings? yes x no

Is new test equipment calibrated before being used for the first time (records,

manufacturer's certificate)? yes x no

Is the test equipment marked with

an ID number? yes x no

next/last inspection? yes x no

Is test equipment calibrated and maintained at regular intervals and/or before

use? yes x no

Are the results recorded? yes x no

TEST STATUS

Are untested, nonconforming, tested and approved goods all identified and

separated? yes x no Is it clear

who is responsible for labelling goods as approved? yes x no

who carried it out? yes x no

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MANAGING FAULTY PRODUCTS

Are there any rules governing faulty products for

incoming goods? yes x no

in-house products? yes x no

regarding

separate storage? yes x no

special identification? yes x no

detection and reporting of faults? yes x no

Are steps taken to ensure that it is impossible to perform further processing on

faulty components? yes x no Have measures been specified for dealing with faulty products after

acceptance (acceptable faults)? yes x no

rework? yes x no

rejection? yes x no

Are faulty products retested? yes x no

CORRECTIVE MEASURES

Are quality records analysed for the purpose of deciding on corrective measures, e.g.

for faulty products? yes x no

for complaints? yes x no

for test results? yes x no

Do records exist right through from their introduction up to the completion of

corrective measures? yes x no

QUALITY RECORDS

Is comprehensive evidence of product quality provided by

test reports? yes x no

certificates? yes x no

Have the archiving period and location been specified? yes x no

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HEALTH, SAFETY AND THE ENVIRONMENT Can you confirm to us that the following environmental regulations have been adhered to?

CFC halon prohibition regulation yes x no

YES, this is stated in the general purchasing terms and conditions and the supplementary conditions for each order.

Prohibited chemicals regulation (ChemVerbotsV) yes x no

YES, this is stated in the general purchasing terms and conditions and the supplementary conditions for each order.

Hazardous materials regulation (GefStoffV) yes x no

YES, this is stated in the general purchasing terms and conditions and the supplementary conditions for each order.

Is it possible to use reusable packaging? yes x no

Apart from reusable packaging, is all the other packaging you use recyclable? yes x no

Are environmental protection aspects a fixed part of your product planning? yes x no

Do you supply products containing PFOS? yes x no

In your company, are

production processes yes x no

supply and waste disposal processes yes x no

products yes x no

regularly reviewed with regard to their environmental impact?

Does the company / site have a systematic process for HSE in place? yes x no

Is the company certified in the field of HSE? yes x no

Certification in the field of environmental protection:

DIN EN ISO 14001 (Environmental) yes no x

(Eco-Management and Audit Scheme) yes no x

When you selected your packaging system, did you investigate its environmen-

tal aspects? yes x no

Do you check and evaluate the environmental protection measures implement-

ed by your suppliers and contractual partners? yes x no

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What commitment to environmental and sustainability issues has/have the manufacturer(s) demonstrated in the last 3 years? Please describe measures using key words and send us any appropriate evidence, e.g. awards, environ-mental prizes, test reports, etc. SEE APPROACH TO SUSTAINABILITY

Have any special measures been taken in order to increase the recyclability of

the products? yes x no

Have the environmental protection measures in your company already been audited? yes no

x

Are environmental protection aspects an established part of your product plan-

ning? yes x no

With regard to environmental protection, does your company comply with for-

mal written guidelines? yes x no

Are environmental protection measures and results documented in your com-

pany? yes x no

In your company, have targets been set for improvements in environmental pro-

tection and do you record the extent to which those targets are achieved? yes x no

Do your employees receive regular information and training on the topic of envi-

ronmental protection? yes x no

Do you check and evaluate the environmental protection measures implement-

ed by your suppliers and contractual partners? yes x no

Is waste in your company collected and disposed of separately? yes x no

When you selected your packaging system, did you investigate its environmen-

tal aspects? yes x no

Are your products manufactured under fair working conditions? yes x no Certification in the field of health and safety in the workplace

OHSAS 18001 yes no x

SCC (Safety Certification Contractors) yes no x

Are the product manufacturers certified in compliance with

a health and safety management system? yes no x

Are health and safety precautions regularly

reviewed by external organisations? yes x no

Note: They are reviewed in the context of ISO 9001.

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Does the company have support with regard to safety systems

and occupational healthcare (ASiG)? yes x no

Does the company have an HSE organisation?

Note: Workplace safety, occupational health, factory security and environmental protection

are the responsibility of the Facility Safety department. yes no x

Are your work procedures documented in written

instructions (e.g. operating instructions, work instructions)? yes x no

Are the responsibilities defined in writing, e.g. in an organisation chart? yes x no Has a factory risk assessment (ArbSchG)

been carried out and documented? yes x no Has a workplace-related risk assessment

(ArbSchG) been carried out and documented? yes x no Are employees provided free-of-charge with personal protective equipment that is suitable for their requirements and is that equipment

maintained and replaced when necessary? yes x no Do all employees (company employees and temporary agency workers) have an appropriate qualification for the work that they are

to perform for the company? yes x no

Are HSE meetings (ASA) held at the company? yes x no

Is the company prepared for emergencies? yes x no (fire prevention, first aid, training) Have those employees who have been assigned responsibilities in the event of an emergency on company premises received the

relevant training? yes x no Is the risk assessment used as a basis for identifying the activities

that require regular occupational health checks? yes x no Are the specific occupational health checks

for employees carried out? yes x no

Are machines, devices and equipment tested regularly? yes x no Within the company, are procedures in place regarding the reporting and recording of accidents

that result in, or do not result in, any disruption to work? yes x no Within the company, are procedures in place to investigate all accidents

that result in, or do not result in, any disruption to work? yes x no