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Defining holistic approaches to a sustainable redesign of an energy efficient factory. Assembly plant Leipzig.

Defining holistic approaches to a sustainable redesign of an energy efficient factory. Assembly plant Leipzig. . Christian Imgrund Manager Facility Planning, Controls Engineering and Structure Planning Assembly Technology BMW Plant Spartanburg. Sheer Driving Pleasure. BMW

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Defining holistic approaches to a sustainable redesign of an energy efficient factory. Assembly plant Leipzig.

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  1. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Assembly plant Leipzig. Christian Imgrund Manager Facility Planning, Controls Engineering and Structure Planning Assembly Technology BMW Plant Spartanburg Sheer Driving Pleasure BMW PlantLeipzig

  2. The BMW Group.Fascination and enthusiasm with the brands BMW, MINI, Rolls-Royce und Husqvarna. • Corporate data 2011. • Sales Automobile: 1.668.982 (+14,2%) .BMW: 1.380.384 (+12,8%).MINI: 285.060 (+21,7%).Rolls-Royce: 3.538 (+30,5%).Sales BMW Motorrad: 104.286 (+6,4%). • Employees worldwide: ca. 95.500.

  3. International Production System.Basis for the high flexibility in the car production. Berlin Motorcycles Dingolfing 5 Series, 6 Series, 7 Series Eisenach Components Landshut Components Leipzig 1 Series, X1 Munich 3 Series Regensburg 1 Series, 3 Series, Z4 Wackersdorf Components HamsHall Engines Oxford MINI Swindon Components Goodwood Rolls-Royce Kaliningrad Steyr Engines Cassinetta Husqvarna Shenyang Graz MINI Countryman Spartanburg X3, X5, X6 Kairo Chennai Rayong Kulim Jakarta Rosslyn 3 Series Production Sites Assembly Joint Ventures Production Partner

  4. The BMW Plant Leipzig.Highly flexible production. Logistics Press Shop Body Shop Assembly Central Office Building Paint Shop

  5. The BMW Plant Leipzig.BMW „made in Leipzig“. • Products: BMW 1Series5-door. • BMW 1Series Convertible.BMW 1Series Coupé.BMW X1.Capacity: ca. 740 Cars per day.. • Jobs on site: currently about 5,200 (including suppliers and service providers), 2,800 at BMW. • Size of the Plant site: 229 ha. • Start of Production.1. March 2005.

  6. The BMW Plant Leipzig.The Competence Center for electric cars. • The BMW Plant Leipzig will be the new Competence Center for Electric Mobility. • 400 Mio. € Investment for the plant expansion. • Around 800 new jobs. • Building of new competencies: electronics / high-voltage technology, lightweight construction, new materials.

  7. The BMW Plant Leipzig. The Competence Center for electric cars. 2011: BMW ActiveE test fleet. 1,100 electrified vehicles based on the BMW 1 Series Coupé. 2013: BMW i3 (Megacity Vehicle). emission-free city vehicle with electric drive and passenger cell made ​​from carbon fiber reinforced plastic (CFRP). 2014: BMW i8. Plug-In Hybrid electric drive and combustion engine, passenger cell made from carbon fiber reinforced plastic (CFRP).

  8. The BMW Plant Leipzig.Vision: CO2-free electricity for CO2-free cars. • Emission-free mobility begins with the production. • Ambitious targets of environmental protection and resource efficiency: reducing energy consumption by 50% and water consumption by 70% per vehicle. • Use of renewable energy for sustainable production: construction of four wind turbines at the site.

  9. The BMW Plant Leipzig.Flexible, communicative, expandable. Blechschalenfahrzeuge Press Shop Body Shop CFRP-Press Shop Paint Shop Assembly Logistics Painted Body Parts Assembly Logistics Body Shop

  10. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Energy allocation in the plant and assembly.

  11. Defining holistic approaches to a sustainable redesign of an energy efficient factory. The breakdown of the energy costs.

  12. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Relevant key figures in the assembly. Electricity 2.800 kW 700 kW 810 kW 220 kW 700 kW 200 kW 170 kW Paint finish 6,0% IT 7% Equipment 25,0% Lighting 29 % Ventilation 25% Small appliances 8% • Snapshot during production. • Data based on the „EnergyAtlas“. • Natural gas only used for heating. • Water (90% washroom and sanitary, 10% process). • Energy structure is completely different than in the rest of the plant.

  13. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. • Skylights in the roof and porches • Natural lighting of the building by using the daylight. • Implementation of a sensor-based daylight control. • Saving electrical energy for lighting the hall.

  14. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. • Exhaust vents with weather protection onthe roof • Ventilation of the hall through the use of natural air currents. • Implementation of a temperature-based flap control. • Saving of electrical and heating energy in the hall / • avoiding a mechanical ventilation in the logistics area.

  15. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. • Ventilation slats in the facade / sun blinds • Ventilation of the hall through the use of natural air currents. • Implementation of a temperature-based control fins. • Saving of electrical and heating energy for ventilation / temperature control of the hall.

  16. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. • Weather resistant roof ventilation system with heat recovery • Innovative air ducts near building columns for perfect ventilation. • Implementation of heat recovery. • Saving of electrical and heating energy for ventilation / temperature control of the hall.

  17. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. • Miscellaneous • Water-saving faucets in restrooms. • Insulated glass windows, bright roof sheets. reduces summer heat. • Enclosed break areas at 70 ° F, Production areas at 66 °F).

  18. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. • Interaction of the Ventilation, heating and cooling systems • Assembly: Ventilation, Heating, Cooling = Roof Vents + Chimney Effect. • Logistics: • Ventilation, Cooling= Chimney Effect, Heating = Radiant Natural Gas Heating • Others: Ventilation, Heating, Cooling = Roof Vents

  19. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. • Compressed air supply via a ring line and branching valves • All consumers can be shut off separatly. • Implementation of innovative service units enables targetedcare and control of the compressed air requirements of all consumers. • Reduce compressed air consumption through demand management.

  20. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. • Motion sensors in restrooms • Automatic switching on and off the lights. • Exhibit space, communication space: LED. • DALI-Light Contolls (Flexible Light Controll System) • Demand-based lighting circuit through virtual rooms. • Media/Supply routes and lighting laterally to the skylights • Reducing shadows and increasing the daylight effect.

  21. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Metering through demand paths. Emergency Power & Lighting Sub-Distribution Small Appliances Equipment Ventilation IT Lighting Power Supply

  22. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Renewable Energies. • Wind Turbines in Leipzig • We use for the production of the BMW i models in Leipzig100% of electricity from renewable sources by generating directon site with the help of four wind turbines. • These four wind turbines will have a total capacity of 10 MW and an annual power production forecast by an average of 26 GWh. • The turbines have a hub height of approximately 140m and a blade length of about 50 m and a total height of 190m. • Construction has begun in July 2012. Commissioning of the turbines and the supply of CO2-free electricity generated there to the factory network will take place in time to the SOP of the BMW i models.

  23. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Renewable Energies. • The Hydrogen Project Spartanburg/USA • The BMW Plant Spartanburg has one of the largest Hydrogen Fleets in the world. (Ziel bis 2013 ca. 300 Stck.) • On site we have 8 hydrogen dispensers. • Daily we use 280 kg of hydrogen at • full production. • The annual costs for material handling • could be reduced by ca. 70%*. • *(Cost comparison: Battery Charging vs. Hydrogen Fuelling.)

  24. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Renewable Energies. • Land Fill Gas (LFG) in Spartanburg/USA • Since 2002 the BMW Plant Spartanburg uses Land Fill Gas to substitute natural gas. • 60% of the gas demand is currently covered with landfill gas. • For this purpose, pipeline (9 miles) from a nearby landfill was built to the plant. • The annual savings are estimated at approximately $ 1 million or 17,000 tons of CO2. • Two new 5.5 MW gas turbines, a Siloxanes LFG cleaning system, 20 bar LFG compressors, $ 12 million investment. • The savings equivalent to the energy consumption of 6,500 single-family homes.

  25. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Renewable Energies. • Solar PV Project in Spartanburg/USA • Installation of the Equipment in 2012. • 392 Bosch PV Modules (240W). • 1 SatCon Inverter (PVS-100-480). • 2 Charging stations for electric cars.

  26. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. „No energy consumption without added value!“ EfficientFacilities • Lightweight construction • Efficient drives • Auto Start Stop • Brake Energy Regeneration • Electric Power Steering

  27. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. Simplified diagram: Basic Load! Today EfficientFacilities • Focus: • No Basic Load. • Energy Reduction (-30%). • Complete Equipment shut down. • Energy consumption transparency. Basic Load Sunday (WE) (non-production)

  28. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Structural Measures. - Responsibility: www.bmwgroup.com/responsibility - BMW EfficientDynamics: www.bmw.com/efficientdynamics - CleanEnergy: www.bmw.com/cleanenergy - Produktion: www.bmwgroup.com/production - Recycling: www.bmwgroup.com/recycling - SocialCommitment: www.bmwgroup.com/socialcommitment

  29. Defining holistic approaches to a sustainable redesign of an energy efficient factory. Thank you! „In future premium will also be defined by sustainability.“ Dr. Norbert Reithofer Chairman of the Board of Management of BMW AG If you have any further questions: Publications: Energy 2.0 03/2011 “GanzheitlicheEnergieeffizienz in derFahrzeugmontage” ATZ Produktion 09/2011 “Ganzheitliche Nachhaltigkeit und Energieeffizienz in der Fahrzeugmontage“ „Holistic sustainability and energy efficiency of the vehicle assembly” Christian Imgrund Technical Planning, Manager Facility Planning, Controls Engineering and Structure Planning Assembly Technology Plant Spartanburg. Christian.Imgrund@bmwmc.com

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