Air League in the Foundry
Compressed air consumption decreased by 15 percent, and employees saved CZK 1.5 million crowns a year.
efore the general company summer holidays took place, the Foundry became
a place for workshops supported by the
GreenOffice department. These launched
the long-term QUEST energy-saving programme. As compressed air is the “heart”
of production plants, it has become clear
that the largest savings can be achieved
by reducing the consumption of pneumatic energy during casting, machining and
maintenance. Therefore, a competition to
reduce compressed air consumption was
announced in the Foundry – the so-called
Air League, which took place from 28 November until 24 December 2016. The management of the Foundry, led by Jaroslav
Müller, as well as representatives
from the Production and Maintenance departments and the ex-
ternal company HE Consulting participated
in the event.
The actual competition was preceded by
trainings during which all employees of the
Foundry learned step by step about the main
features of the Air League, in which individual shifts and departments competed against
each another. They were further subdivided
according to their specialisations – casting,
machining and maintenance.
And which activities helped reduce compressed air consumption? The elimination of
leaks, optimisation of everyday activities on
the devices, shutdown of unused ones, pressure adjustment and timing.
What was important, however, was the feedback the employees regularly received and
how well they did, scoring one point for
every percent saved up. It was interest-
ing to see the teams enthusiastically compete against one another and the amazing
final results they achieved.
The Foundry managed to reduce its compressed air consumption by 15 percent in December, a decrease of 1.5 million crowns a
year, which was positively reflected in the
price of each casting that ŠKODA AUTO released on the market.
The winning teams in casting, machining and
maintenance will be rewarded, as will individuals, who will receive additional special prizes in February this year.
Under the QUEST energy-saving programme,
the car company will continue to ensure that
energy is saved as much as possible. Therefore, another Air League started at the end of
January. This time, the competition will take
place in the Forge! Michal Beneš
PAYS CZK 450K
AIR EVERY WEEK!
Lamp replacement in hall M12A
More economical and adjustable LED technology replaced outdated discharge lamps
Lamp replacement was taking place in the hall under full operation.
he launched replacements of lighting
systems in production and non-production areas of ŠKODA AUTO are continuing
with success. The currently used lighting systems, which generally consist of outdated
discharge lamps, are very energy-demanding,
and their maintenance is very costly. Therefore, they are gradually replaced with new
lamps using the LED technology with a sophisticated adjustment, control and visualisation.
In recent months, the lighting system in Press
shop M12A has been reconstructed under the
professional supervision of the GreenOffice
and Construction and Infrastructure Planning
departments, as well as in collaboration with
the staff of the PFO-P department. The hall is
unique not only for its height of 17.5 m up to
the truss space level but also for the placement of its sizeable technological equipment.
So it was not easy to meet the requirement
for high lighting intensity (as much as 500 lx)
and at the same time to prevent too disruptive a glare due to frequent manipulation
with gantry cranes. The implementing team
also had to ensure the replacement under full
operational conditions without any downtime
The original lightning system, composed of
discharge lamps with power of up to 2,000 W,
was replaced with LED lamps of only 200 W
of electric energy consumption, which are
fully adjustable depending on the daylight
intensity. The connection of programmable lamp stabilisers with the control system
is provided by the DALI bus. The lamps supply five new switchboards that communicate
with each other through the RS 485 serial
line. The system is also connected to the corporate data network via an Ethernet interface
(known as a LAN). The advanced system enables visualisation, adjustment diagnostics of
the lamps, creation of light maps or displaying
and archiving a multitude of parameters monitored in a modern shop floor. ŠKODA AUTO
is also working on visualisation and connection to the control system through a Web interface, which will provide the possibility of
predictive maintenance and system management without need for a technician.
Electricity savings, which in this case amounted to more than 2,000 MWh annually, confirmed the meaning of the GreenFuture
concept with the return of the whole investment in 2.5 years.
It is quite obvious that the direction set by
the GreenOffice department and the implementation team with the support of the
group Umweltforum is very effective at creating savings – not to mention the improvement of working conditions for all employees,
whose satisfaction is always the best of
feedbacks for the installation team. Pavel
Mates, Pavel Jaček
Employees of ŠKODA AUTO can
come up with their own proposals
to improve environmental
he motivational event GreenZ.E.B.R.A.
was extended with modified terms
for 2017. The objective remains the
same: to focus the activity of all ŠKODA
AUTO employees on environmental
A proposer must be a tariff employee of ŠKODA AUTO at the time of
registering their proposal, and their
Z.E.B.R.A. (Improvement or Order proposal, except for the one from the
KVP workshop) proposal needs to be
submitted and registered in the set
time frame. If implemented, the proposal should have a quantifiable contribution. A special prize: According
to ON.1.030, a reward for quantifiable contributions will increase by 20
percent and will be established from
the expected contributions for the
first year of use. One of the proposers will be drawn and receive an electric bicycle from the ŠKODA AUTO
collection. The draw will be carried
out by the SP/2 Design centre department with a drawing programme.
Proposals that are not included in the
event are clearly defined in the conditions. RED
AdBlue dispenser in the
n 12 January 2017, an AdBlue dispenser was put into operation at the petrol station. Those who use business
diesel cars with the SCR technology can
now easily replenish AdBlue the same
way they refuel. This eliminates the complex and lengthy refilling of AdBlue from
plastic canisters, which will simultaneously reduce the production of plastic
waste. Refilling of AdBlue for passenger cars right from the dispenser is still
very rare, and ŠKODA AUTO is among the
first operators of such technology in the
Czech Republic. Michal Jirouš