manufacturing excellence for resource efficiency … · manufacturing excellence for resource...
TRANSCRIPT
Hospital – UK
MANUFACTURING
EXCELLENCE FOR
RESOURCE
EFFICIENCY
Christophe D’Amico
Operations Director
November2015
March 3rd, 2015
Tark
ett
–All
rights
rese
rved
Agenda
Tarkett Group presentation
Manufacturing excellence and Environmental policy at Tarkett
Tarkett GDL: the case for resource efficiency
Energy efficiency
Recycling
Conclusion
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1.3 million
square meters
of flooring
sold each day
Sales in more than
100 countries
Net Sales*:
2.4 billion euros
EBITDA*:
275 million euros
12,000employees
34Industrial sites
*Net sales 2014 ; Adjusted EBITDA 2014: Adjustments include expenses related to restructuring, acquisitions and certain other non-recurring items.
Global Leader in Innovative Solutions for Flooring and Sports Surfaces
2014 Figures
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A broad product portfolio for integrated solutions
Vinyl Linoleum Wood Laminate
Rubber Carpet Artificial Turf Tracks
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Market expertise for all end-use segments: Residential (40%) and Commercial (60%)
Retail & Hospitality
HealthcareHousing
Offices Sports
Education
80% Renovation - 20% New construction
2014 Figures
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Proximity to
client matching
local demands
& norms
Optimised
transportation
cost & import
taxes
Better supply
chain lead
time & flexibility
34Industrial Sites
A worldwide
operational
excellence
program
Achieving best-in-class industrial and logistic footprint
2014 Figures
– WCM is a continuous improvement program based on TPM and LEAN philosophy and tools
– Launched in 2009 in Tarkett pilot plant in Sweden, it has been since rolled out to all production sites in Europe, Eastern Countries and North America.
– A central experts team supports its implementation by local WCM managers and pillars leaders
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From the Historical Linear Economy…
…to a profitable circular economy model
Produire
UtiliserRecycler
Tarkett uses a systematic
approach and tool to
perform its transition
Tarkett Invests and Innovates for Sustainable Growth
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Achieving resource efficiency through Manufacturing excellence
Integrated sustainability :
Identify problems to be addressed
Priorize based on Safety, Environment, Service, Quality and Productivity criteria
Detect, Observe, Understand how they are created, how much they are.
Analyze why and choose relevant WCM tool
Implement solutions with rigor
Check results and efficiency
Standardize to ensure sustainability and transverse lessons learnt
WCM way appliesto Environment as the others pillars
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Objectives for the Environment
Pillars Initiatives 2020 objectives KPI
The responsible use of natural and non-renewable resources in our operations
Reduce usage of fresh and potable water
100% of our manufacturing sites haves implemented closed-loop water circuits
Water consumption
Decrease energy consumption and greenhouse gas emissions
20% reduction of GHG emissions against a 2010 baseline
Energy use
CO2 emission
All waste and productsat end-of-use enter intoa biological or technical cycle
Ensure that all manufacturing waste enter into a biological or technical cycle
0 industrial waste going to landfill
Internal Recycling (Restart program)
Waste for Landfill Hazardous waste External Recycling
To achieve Tarkett 2020 objectives : group factories use the following indicators
In 2015, objective in Clervaux factory is to achieve 5% improvement of resource efficiency on water and energy usage, waste management
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Optimize energy consumption and develop the use of renewable energies within Tarkett group
Biomass
Solar Wind
Recovery of wood sawdust for heat and energy production (BačkaPalanka, Serbia)
Solar panels installed in Netherlands, Belgium and Italy
Wind turbines installed at Waalwijk, Netherlands (Desso)
Geothermal
Use of underground heat to warm up or cool down the production environment (Narni, Italy)
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Tarkett & GDL
Tarkett GDL in Lentzweiler
Residential European Supply Centre (12 000 m² storage building)
170 000 m² of industrial land
50 000 m² of industrial/logistic building
Multi technology (recycling, calendaring, coating, extruding)
Production running 5 to 6 days, 24 hours
500 Headcount
R&D in Wiltz
Worldwide R&D Centre
3 000 m² of industrial building
Pilots lines of all vinyl production process
70 Headcount
Luxembourg City
2015 JulyWCM Audit Clervaux
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Improve energy efficiency
Energy efficiency approach based on 3 axes
Multiskilling, multidisciplinaryKnowledge exchange and global
approach
Technical Detection and elimination of NRJ over-consumption, planning and implementation
Management Establish a management system of NRJ performance Implementation of energy team Learning Factory : 4 Tarkett experts have followed a 52 days training program
Mindset Green Tour to promote importance of energy savings Awareness campaign on energy EMAT (Environment Management Audit Tool) to have dialog with every employee Submit ideas for improvement to eliminate and prevent problems (Quick Kaizen)
Controling Engineering Maintenance Production
HSE
NRJ projects Industrialization
Towards ISO 50001 certification of energymanagement system in December 2015
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Learning Factory
Targets :
Energy cost savings and Environmental Impact (CO2 saving)
Increase the competitiveness of Luxemburgish companies
It’s a project founded in June 2013 by the Luxemburgish government with different
partners
Ice tea production line
Real production equipment
Cost : 2 million €
Energy efficiency approach based on 3 axes
Production same quantity, same
quality, with less energy
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Energy, what we did
1.6 1,5
0
0.5
1
1.5
2
YTD May 2014 YTD May 2015
KPI NRJ kWh/m²
80 K€ energy savedwith insulation of more 600 valves0,38 year payback
8 K€ energy savedthroughcompressed air leaks detection and repair of more 30 leaks points
Resource efficiency contributes to financialperformance and plant profitability in 2014 :
• 5% Energy costs reduction thanks to energysaving projects
• 6000 Kwh electricity saved per year• 1600 tons of CO2 reduction
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Energy, what we will do
2015 JulyWCM Audit Clervaux 19
CO2 emission for energy transformation
Investment
K€ saving (-5% energy invoice)
0
0
200
AdvantageBiomasse NRJ instead gas and electric NRJ (boilers and chillers)
Third party investor to have injection rates for green NRJ
Biomass less expensive than gas and electricity
Biomass comes from local forestry and woodprocessing factories (sawdust and cutting residues)
Biomass : towards greener energy in Clervaux
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Recycling, what we did : Reuse program
The recycling of Tarkett plants post industrial waste
to design new products with good materials
Up to 53% of recycled material content in new vinyl flooring
Recycling programs
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Recycling, what we will do
Partnerships with customers, installers, recollection companies and waste management companies
To recycle good materials
ReStart vinyl recycling program for professionals
Creating ReStart recycling programs globally
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Green Tour
Inauguration by Michel Giannuzzi, Tarkett CEO. 10th Sept. 2015
Eco Cluster Lux Innovation. 28th Oct. 2015
Fedil, Learning Factory and Portes du Luxembourg. 1st Oct. 2015
Archigroup. 5th Nov. 2015
Tarkett EMEA division. 17th Nov. 2015
Ronneby Swedish Factory. 15th Oct. 2015
To explain and show the application of Tarkett’s sustainable development strategy in a production facility
Tark
ett
–All
rights
rese
rved
Conclusion
Tarkett Factory in Clervaux has become a model of industrialand environmental performance for the Group
Key succes factors:
Full integration of both industrial and environmentalstrategy at the highest level of management.
Systematic use of robust continuous improvement tools
Involvement of all employees
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