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Building
No. |
Object |
m² |
|
A |
Workshop |
2,421 |
|
D |
Office
building |
717 |
|
F |
Pent-roof |
60 |
|
Total
built-up area |
3,198 |
|
The
following companies are located not further than app. 1 km from the 
site:
-
Fischer Mössner GmbH & CoKG
-
Franz Schwarz Reise-, Autobus- u. Güterbeförderungsunternehmen
-
Tupperware - Orthaber Ges.m.b.H.
-
Vescon Systemtechnik GmbH
-
Magna Heavy Stamping
5 Quality and
environmental policies
Customer satisfaction
Our
first target - responding to our customers’ needs and requirements –
is realized by individual planning and counseling. Always taking into
account the environmental aspects of our activities is an integral part
of our quality performance.
Staff
The
company’s staff is its most valuable resource. Excellent quality
performance and environmental awareness as well as active responsibility
and careful planning for the future are encouraged by specific training
programs and by assigning new responsibilities.
Suppliers
By
carefully choosing and assessing our suppliers we try to reduce the
necessity to inspect incoming goods and achieve a constant level of
quality performance for bought parts. We expect our suppliers to adhere
to our company’s quality and environmental performance and support
their implementation.
Authorities
Ges.m.b.H. meets the basic requirements of compliance with applicable
legislation and technical guidelines. In addition, the company strives
to maintain good relations with the authorities.
Communication and
environmental awareness
Ideas
and suggestions – in-house and other – on how to optimize operations
are always welcome and, if possible, realized. We adhere to the
principles of avoiding or separating waste, reducing resource
utilization, as well as implementing and promoting energy saving
measures, thus playing an active role in the protection of the
environment.
Facilities
The
company’s machines and facilities, at the highest-possible level of
technology, are operated in accordance with the respective regulations
applicable and checked on a regular basis.
System
Deficiencies
in quality and environmental issues are to be prevented at all cost. As
a preventive measure, irregularities are recorded, analyzed and
counter-acted accordingly. Regular evaluations are carried out to check
the effectiveness of and compliance with these measures.
By
setting concrete environmental targets we commit to continual
improvement and to the prevention of negative impacts on the
environment.
Each
member of the
staff is responsible for the implementation of this environmental policy
in his/her field of activities.
6
Environmental
management system
The
environmental management system at Ges.m.b.H. conforms to ISO 14001
requirements.
6.1 Documentation and
control
The
environmental management system is documented in the management manual,
in procedures and work instructions as well as in instruction folders.
The
system representative is responsible for compiling and distributing
management documents. She is also in charge of managing and evaluating
all data regarding the environment. In-house environmentally significant
inspections are carried out by trained staff or handed over to
specialized companies. Environmentally significant consumption data are
compiled on a monthly basis and analyzed once a year. This system of
monthly records of environmental data allows us to recognize trends,
analyze fluctuations and take measures in time to prevent possible
environmental hazards.
6.2
Suppliers
The
company also carries out a yearly assessment of the supplying companies.
One of ‘s
criteria in choosing partners is their environmental awareness.
6.3
Communication
In
the course of in-house training programs, we raise awareness of the
environmental aspects of our operations. Information on environmental
issues is relayed to our staff by way of notices and memos.
Suggestions
from the staff or external sources are handled by the system
representative who then redirects them to the management.
6.4
Legal compliance
The
management is responsible for compliance with legal constraints.
Ges.m.b.H. are recorded in a list of laws. The company’s membership in
a legal database guarantees that the list is updated on a regular basis.
The management is in charge of introducing all measures resulting from
decrees and legal constraints. The system representative has to make
sure that these measures are implemented.
6.5
System evaluation
An
internal management system assessment is carried out at least once a
year. The effectiveness of the environmental
management system and the staff’s current standard of knowledge are
checked by way of internal audits. The final audit report serves as
evaluation basis for the company management. In addition, the management
system is also evaluated at least once every year.
This
yearly evaluation comprises legal compliance, the implementation of
environmental targets, accordance with environmental policy, possible
cases of environmental emergencies and all environmentally significant
data.
The results of this
assessment form the basis for the formulation of new environmental
targets and the development of an environmental program which will lead
to continual improvement of our environmental performance.
7
Process analysis
Process diagram
7.1 Main processes
PLANNING
Planning,
development and construction of components for all fields of
environmental technology custom-made according to the requirements of
individual customers with regard to technical standards and in
compliance with regulations as to environmental and quality performance.
PRODUCTION
Single-piece
production of structural steel elements and machines, as well as
assembly of manufactured or external components, using appropriate
process and auxiliary materials. Environmental and quality checks and
intra-company maintenance work to ensure optimal working condition of
all machines, compliance with all legal/prescribed requirements and
keeping technical standards up to date.
INSTALLATION
On-site
assembly of orders in accordance with written instructions, assembly
control, site supervision, final controls.
Management
-
Investments, financing projects, insurance, sales
-
Strategic planning, company policy, environmental and quality performance, specification of preventive and corrective measures, assessment of management system
-
Personnel procurement, personnel selection, approval of organizational structure
-
Training programs, staff motivation, occupational safety
-
Contacts to the official authorities, laws and regulations/administration
Administration
-
Accounting, bookkeeping, payroll accounting
-
Statistical cost accounting
-
Secretariat, telephone switchboard
Quality and environmental management
-
Establishing quality and environmental management systems
-
Documenting process development
-
Carrying out and documenting the internal environmental audits
-
Compiling and analyzing environmental data
-
Listing environmentally significant facilities, materials and activities
-
Evaluating the necessity of training programs, carrying out in-house training courses in the fields of quality assurance and environmental protection
-
Error analysis, assessment of nonconformance costs
-
Supplier evaluation
-
Assessing the effectiveness of measures taken
-
Monitoring Legal Compliance
- Emergency planning (Checking the fire protection plan, managing safety data sheets, checking the first aid kit and fire extinguishers, informing the staff, practice alarms, etc.)
Sales
& cost accounting
-
Customer acquisition
-
Preliminary project costing
- Submitting offers, drafting and concluding contracts
Order
processing
-
Project management, coordination and planning
-
Customer communication, project requirements and documentation
-
Supervising and controlling design and construction
-
Purchasing/external production
-
Supervising project progress
-
Compiling manuals
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Transport organization, assembly planning
-
Acceptance
-
Billing
Storage
-
Stock management, materials receiving, inspection of incoming goods
-
Material supply
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Inspection of outgoing products, packaging, dispatch, loading
-
Handing out and checking safety equipment and safety gear
- Internal maintenance of machines and facilities
7.4
Input/output
The
comparison of set targets and achievements is aimed at assessing the
company’s targets regarding environmental protection in the initial
phase of a project. The results of this analysis form the basis for
setting concrete environmental targets in the framework of developing an
environmental management system and for documenting the environmental
impact of the site. Extensive records and documentation of specific
information are elementary for the detection of environmentally
significant weaknesses and the development of counteractive measures.
The analysis includes all sections of the company, from production to
power supply and administration.
7.5
Priority list for
input materials
In
the course of the internal environmental audit the input materials most
significant to the environment were determined as follows:
The
stripping agent Antox 71E shows the highest environmental relevance.
Because of its composition, the agent is poisonous for humans and for
the environment (groundwater). Since this agent is exclusively used for
the treatment of welding seams during assembly and no alternative
treatment with results of the same quality could be found, our skilled
workers receive regular and especially thorough training in handling
this material.
All
materials are recorded in a materials list and assessed on the basis of
environmental and safety criteria, taking into account the respective
safety data sheets.
In
addition, our skilled staff takes part in emergency drills to prevent
incidents with a possibly harmful impact on the environment.
7.6
Priority list for
output materials
The following
priority list shows the results of the assessed output materials with
regard to their environmental relevance:
The maximum point value for environmental relevance comes
to
82.5; the minimum value is 0 points.
Oily
waste shows the highest degree of environmental relevance in our
company. However, due to its low accumulation quantity, oily waste
presents only a minor hazard to the environment. To prevent a possible
negative impact, our staff is instructed in the correct handling of
these materials.
7.7
Environmentally
significant activities
Environmentally
significant activities were assessed to establish the need for specific
training courses. The following activities are environmentally
significant:
|
1 |
stripping |
-
waste water and
soil contamination, health hazard |
|
2 |
fork
lifter |
-
noise, energy
consumption, danger of accidents |
|
3 |
welding,
plasma cutting |
-
exhaust air,
noise, energy consumption |
|
4 |
drilling,
lathing, milling |
-
waste
water, energy consumption, waste materials,
noise |
|
5 |
cleaning
|
-
waste water,
energy consumption, waste materials |
Internal
training courses for specific topics are held by the responsible number
of staff,
training sessions for individual systems are carried out by the system
representative.
In
instruction and training courses, the members of the staff are informed
about the environmental relevance of their activities and possible risks
and hazards. These measures are undertaken to increase awareness of
environmental protection, which in turn will help prevent future
hazards.
7.8
Environmentally
significant facilities
In
the course of the initial revue, no environmentally significant
facilities requiring adjustment were discovered. By way of job
instructions drafted beforehand and specific external training programs
we were able to minimize operation of these facilities and, as a
consequence, the possible danger caused by inappropriate handling.
In-house maintenance schedules were devised to ensure optimum
functionality. All internal maintenance tasks are performed by
specifically trained workers.
In
the course of the assessment of facility performance all facilities were
recorded and their technical standard evaluated.
8
Analysis of the site’s
impact on the environment and the
aspects examined
Power
is supplied by the local electricity plant (Feistritzwerke Gleisdorf);
power consumption is recorded separately for engineering office and
workshop.
Power-saving
facilities and operation were already taken into account in the planning
and construction phase of the workshop. The windows are arranged in a
way (ceiling light domes and continuous window fronts along the walls)
to make full use of daylight and minimize the need for electric lighting
which is provided through low energy light bulbs. In 1997, welding
machines with high input power were replaced by up-to-date units with
lower input power rates at equal performance levels.
In
the engineering office, electricity is used to operate CAD and EDP units
and other office equipment, and for lighting purposes. The office staff
are instructed to avoid unnecessary energy consumption by switching all
office equipment to the energy-saving “standby mode” when possible.
8.2 Heating
All
buildings at
Ges.m.b.H. are heated by natural gas. The heating system consists of two
condensing boilers (1994 model, ELCO KLÖCKNER, ULTRON 40 SG, each with
a nominal heating capacity of 38.2 – 41.4 kW) feeding the central
heating system in the office and the workshop which is regulated by a
thermo regulator for night-time and weekend heating reduction, but can
also be adjusted according to individual specifications. Office
radiators are also equipped with thermostat valves.
Additional
heating in the manufacturing shop is supplied by 5 Ucotherm hot-air fans
with a nominal heating capacity of 47.3 kW (40,700 Kcal/h) and an
effective heating capacity of 42.78 kW (36,792 Kcal/h).
The
heating system is checked every month and thoroughly inspected and
serviced annually by the company’s own personnel as approved according
to trade law, as well as by a certified chimney sweep. Official waste
gas measurements are not required.
8.3 Gas
The
company’s heating system is powered by natural gas. Industrial gases
are used for welding and cutting in the manufacturing department.
8.3.1
Natural gas
consumption
Natural
gas is used for heating purposes only and consumption is therefore not
dependent on production. The amount of gas used for heating depends on
the climate. To keep energy consumption at a minimum level, thermal
insulation was a top priority when the buildings were first constructed
(full heat protection, special flooring in the manufacturing building,
thermopane glazing).
8.3.2
Industrial gases
The
following gases are used in production: oxygen, acetylene, argon,
forming gas, corgon 18, nitrogen and mison. The gases are bought in
deposit containers.
As
per official notification, the containers are stored in a certified gas
storage area. The amount of gas required for production is kept with the
machines in the production area. The gas bottles are handled according
to technical safety regulations. Those members of the staff authorized
to transport gases are instructed every year as to the handling of
industrial gases and possible hazards.
8.4
Liquid energy
sources/fuel
The
company employs passenger cars / vans and a
fork lifter. The company vehicle mileage is relatively small. Vehicles
do meet the latest technical standards. In
the long term, improving technical standards is one element of raising
environmental performance. Service and maintenance are carried out
regularly in a specialized workshop, the vehicles are cleaned in a car
wash outside the company.
Vehicles
are either employed as company cars or for assembly purposes.
Fuel
consumption depends on the number of call-outs and the distances
covered. The fork lifter is used in the workshop to move freights and
for loading and unloading. Cutting down on fuel consumption is only
possible by instructing the staff how to handle the vehicles carefully
and economically (not to leave the motor running,...). It is, however,
not possible to produce figures to prove these instruction measures.
By
providing railway transport facilities on the site we strive to move
most of our products by railway, thus cutting down on energy
consumption.
8.5
Water
Water
is provided by the public water supply of the Municipality of Gleisdorf.
8.6
Waste
water
Waste
water is produced in sanitation and is disposed of through public canalization.
Compressed
air is used in various machines and in the sand blast system and is
produced by a screw compressor. The
screw compressor is checked by the staff every week, a security check of
the pressure vessel facility is carried out by the TÜV every 5 years.
During the in-house check, a leak test of the compressed air facility’s
piping system is carried out. Leaks are repaired at once to avoid energy
losses.
8.8 Waste
At
,
waste is generated in the office as well as in the workshop. The company’s
waste control number is: 00943116.
Waste
oil and oily waste are considered hazardous, the company‘s disposal code is 54 102.
To
keep the amount of waste at a minimum, packaging materials are re-used
by the suppliers (e.g. cardboard and synthetics).
Waste
disposal is carried out by certified waste disposal companies and at the
respective public waste collection points.
One
of our most important targets is to segregate waste as efficiently as
possible in order to reduce disposal costs. Therefore we have introduced
an internal waste separation system.
8.9
Emissions
- dust - odor
Insignificant
emissions develop in the form of welding smoke and are created by the
glass bead blasting system. They are only significant in connection with
occupational safety, but have no impact on the environment. Since
is exclusively engaged in single-piece production, welding is only
necessary at certain times, and the glass bead blasting system is only
in operation when required. The aforementioned emissions are therefore
restricted to these times. The welding foam is released through an 18 kW
bag filter unit with a maximum of nine suction points.
The
glass bead blasting system is equipped with a bag filter unit consisting
of 86 tubular filters made from polyester needled felt with a total
filter area of 110 m² and a degree of purification that amounts to
98.9%. Pollutants caught in the tubular filters are collected using
vibration motors and pass into dust catchers through collection funnels
and gravity flaps. A display on the filter unit shows the efficiency of
the filter. The dust collected by the filter belongs to the category of
residual waste and is disposed of accordingly. The glass bead blasting
system does not cause harmful impacts on the environment. As a rule,
app. 80% of the cleaned air are returned to the blast chamber, 20% are
released into the atmosphere. The remaining facilities on the site do
not cause emissions.
No
odor emissions are released by .
8.10
Noise
On-site
noise is mostly limited to traffic noise generated by the transportation
of raw materials and finished products to and from the premises.
Production noise is significant for occupational safety but has no
influence on the environmental impact of the site.
8.11 Soil
Except
for a small green space, the site premises are almost completely covered
with asphalt. Special flooring is provided in the production area of the
workshop. When necessary, storage areas for environmentally significant
materials are equipped with appropriate collecting pans to prevent
accidental spilling or overflowing of liquids onto the workshop floor.
9 Prevention of
accidents and incidents
The
following preventative measures were taken to avoid environmentally
significant incidents and accidents on the area and to minimize the
risks:
Environmental
management system
Implementation
and extension of the environmental management system, assessing
environmentally significant factors and introducing of preventative and
corrective measures.
Fire
protection plan
The
fire protection plan contains all technical fire fighting information
and equipment (location of fire extinguishers, emergency exits).
Hazardous
materials
Assessment
of all environmentally significant materials by way of safety-data
sheets. Their use is approved by the system representative. Registration
in the list of environmentally significant materials and, if necessary,
training courses for staff members by means of safety-data sheets. These
contain properties and instruction as to the handling of these
materials.
Oil
and varnish storage area
Construction
of a suitable collecting pan to prevent accidental spilling or
overflowing of liquids onto the workshop floor.
Gas
storage area
Gas
bottles may only be handled by members of staff authorized and appointed
in writing to minimize the risk of accidents.
Training
programs/instruction courses
Regulations
as to handling and storage are followed and all activities are carried
out according to safety-data sheets.
9.1 Raw materials,
process materials and
operating materials
Regulations
as to handling and storage are followed and all activities are carried
out according to safety-data sheets.
-
Inflammable materials are only stored in small quantities in appropriate restricted areas.
-
Water endangering materials (oils) are stored in separate storage areas due to their possible risk to the environment. These storage areas are equipped with suitable oil collecting pans to prevent oil from spilling in the workshop area.
-
Toxic materials (Antox 71 E), which can only be procured with special permission, are locked into the depot and are only dispensed to trained members of the staff when required.
10
Final
analysis of environmentally significant aspects
The
individual priority lists for input materials, output materials,
environmentally significant activities and environmentally significant
facilities were combined in a final diagram to permit an overall
analysis of environmental aspects.
The
following diagram shows the extent of the individual environmental
aspects created by the
site:
The
diagram shows clearly that the environmental criteria waste and
potential accident risk are the most significant factors at ,
followed by energy, air emissions, risk of ground water pollution, soil
contamination and odor emissions.
The
environmental program and the measures to be taken were defined on the
basis of this final analysis.
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ENVIRONMENTAL
TECHNOLOGY Industriestrasse 32, A-8200 Gleisdorf, Austria Tel: ++43/3112/4057-0, Fax: ++43/3112/4320 |