Continental Teves is one of the world’s leading automotive industry suppliers. Founded in 1871, the company operates in 39 countries and is the second largest automotive supplier in Europe. The Continental Teves plant in Ebbw Vale produces automotive brake callipers for high performance vehicles.
Following the initial engagement (CAP) at the Ebbw Vale site in 2008, RUMM were asked to provide a site-wide solution that would reduce energy use across the site without impacting on production output. Key to the plan was a Partnership approach to utilise the on-site knowledge.
RUMM initially installed 25 electricity meters which were linked to a RUMM PULSE unit that collected consumption data. This was then fed into IBASS, RUMM’s Internet Based Analytical Software Suite, in order to assess where energy was being used, and equally where it was being wasted.
Projects undertaken have included:
• The refinement of the low pressure and high pressure compressed air systems.
• Modifications to lighting controls and types of lighting.
• A campaign of raising energy awareness on the shop floor via a ‘Make Every Day Xmas Day’ initiative. This highlighted the fact that it is the lowest consumption day of the year on most manufacturing sites and encouraged employees to try and replicate this over the year.
• The control of production machinery and their ancillary systems.
A return on investment plan to spend £100k in order to save £100k in 1 year was delivered. The review report revealed a further 20% savings opportunity across all projects evaluated.
Why it Worked
A comprehensive RUMM energy management solution combined with full support and commitment from everyone at Continental Teves ensured a successful campaign.