Continental 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 niche and high performance vehicles.
Following Consultation and Planning
at the Ebbw Vale site in 2008, RUMM were asked to provide a site-wide solution that would reduce energy across the site without impacting on production output. Key to the plan was a partnership approach.
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 over the last 3 years have included refinement of the low pressure and high pressure compressed air systems, as well as modifications to lighting controls and types of lighting. Further measures were also implemented including raising energy management awareness on the shop floor via a ‘Make Every Day Xmas Day’ campaign. 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. Also targeted was the control of production machinery and their ancillary functions in order to create a detailed picture of specific energy consumption during particular periods of operation.
Against a return on investment plan to spend £100k in order to save £100k in just 12 months, we achieved the strategy, on ROI in 1 year. The first quarterly report revealed a circa 20% savings opportunity across all projects evaluated. RUMM continues to work with Continental on a performance based contract since then with the objective of delivering savings over the long term.
WHY IT WORKED
A comprehensive RUMM energy management solution combined with full support and commitment from everyone at Continental Teves ensured a successful campaign which continues to generate results.