AŽD Praha - AZD

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AŽD Praha Fast, safe and environment friendly

Transcript of AŽD Praha - AZD

Page 1: AŽD Praha - AZD

AŽD Praha

Fast, safe and environment friendly

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Integrated management systemThe integrated management system (IMS) guarantees quality, safety and environmental compatibility of the wide range of AŽD Praha activities. The system of management is in place also in the area of environmental protection including certification under ČSN EN ISO 14001 and is subject to regular certification process by EZU Praha - Troja.

EducationSystematic education of AŽD Praha staff in specialized areas of environmental protection (water, air, waste, landscape, chemical substances and preparations, energy saving) as well as application of environmental friendly technologies is the company‘s contribution to sustainable development of the society.

MarketingAwareness of the market demands and ecological parameters in the segment of security technology is crucial for the success of the company’s products and technologies with customers.

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Research and developmentResponsible approach to the development of new products and security systems minimizes environmental impact. We focus on the decisive stages in the life cycle of a new product. We analyze material inputs from the point of environment protection, energy intensity, the product future after its expiry and possibilities of recycling.

Design workHigh quality preparation of structures in the design stage and accommodation to all requirements set by state administration authorities in the area of environment guarantees compliance with legislation and optimization of costs during the construction.

BusinessThe selection of a responsible subcontractor and well designed contracts guarantee the quality, safety and environmental compatibility of works included in the contract.

ProductionModern machining centers used in mechanical engineering contribute to environmental performance. Adoption of high technology in the areas of electronics and population of printed circuit boards forms the basis of high quality of components for own products and for external customers.

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AssemblyAssembly work on landscape line constructions requires careful and responsible attitude to the environment. The construction staff and management are obliged to comply with all the decisions of state administration authorities in the area of water management and environmental protection.

LogisticsModern fleets meeting the mandatory emission limits provide for supply of material to the manufacturing and assembly plants of the company and secure supplies for our customers.

ServiceThe decreasing number of service calls concerning the security and communication systems reflects the quality of AŽD Praha products. The service area is also governed by the motto “Fast, safe and environment friendly”.

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The introduction of the quality manage-ment system under ČSN EN ISO 9001 in 1997, which partially addressed environmental issues, brought the sys-tem of company management also to the area of development and protection of the environment. The process of detailed identification of environmental issues within the company started at the end of 2003 and was finished in the first half of 2004 by the initial envi-ronmental review of the entire range of activities. Research and develop-ment, design, production, service and logistics – all these areas were subject to the review. The process of certifica-tion of the environmental management system was finished by awarding the certificate under ČSN EN ISO 14001 to AŽD Praha and all its organizational units. A demanding certification audit was performed by EZU Praha – Troja, a certification body.

The backbone of AŽD Praha system management in the area of environ-ment consists of a set of six directives issued by the company headquarters:

RSP-SM-144/01Traffic/Operation management in EMS

RSP-SM-144/03Environmental protection in objects managed by the company headquarters

RSP-SM-144/05Management of chemical substances and compounds

RSP-SM-144/06Waste management

RSP-SM-144/07Management of operations of ZTE (technical plant) and DSE (service division) in the area of environment

RSP-SM-144/08Water management, air protection, nature and landscape protection, prevention of environmental damage

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The process of integration of the com-pany management systems was completed in 2005, and the integrated management system (IMS) was intro-duced, consisting of:

QMSQuality management system

EMSEnvironmental management system

SM BOZPOccupational safety and health management system

The IMS is subject to supervision audits annually and to recertification process every three years. The latest recertifica-tion audit by EZU Praha – Troja was performed in January 2012.

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AŽD Praha presents itself as a com-pany which through its “Integrated Management System (IMS) Policy” stresses not only quality, safety and occupational safety and health, but also environmental protection, achieved by:

• continuously improving the standard of management in the care for the environment and prevention of pollution

• efforts to eliminate or minimize nega-tive impacts of its activities, products and services on the environment, health of employees and residents in the vicinity of its plants and structures,

• continuous and consistent analysis of raw and other materials, focusing on their maximum utilization and minimizing waste from technological processes and construction,

• observing the principle of sustainable development, with emphasis on the effective use and introduction of technologies and devices friendly

to the environment, respect for expert opinions and proposals for effective prevention of negative impacts and accidents, including their consequences.

ENVIRONMENTAL POLICY

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One of the main priorities in the human resources policy is consistent improve-ments to working environment based on environment friendly technologies used in manufacturing, assembly as well as service areas. First aid courses, training of action following leakage of pollutants into water and handling hazardous substances are organized for employees. All the managers, specialized staff and professionals in the area of environmental manage-ment are included into the company educational scheme. Staff authorized with management of processes related to the environmental issues are employed in each organizational unit.

HUMAN RESOURCES POLICY AND ENVIRONMENT

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Following the Directive 2002/95/EC of the European Parliament and of the Council of 27 January 2003 on the restriction of the use of certain hazardous substances in electrical and electronic equipment, the company had to deal with these issues. Under the Directive, electrical and electronic equipment launched to the market after 30 June 2006 must not contain: lead (Pb), mercury (Hg), cadmium (Cd), hexavalent chromium (CrVI), polychlorinated biphenyls (PBB) and polybrominated diphenyl ethers (PBDE). The application of the Directive was re-flected in the amendment to the Waste Management Act, No. 185/2001 Coll.

In the context of AŽD Praha, this mainly included mastering the lead-free soldering technology outside the area of security and communication technology.The task was resolved by Production Plant Brno within the framework of technical development project. An internal documented procedure was issued covering the technology of lead-free soldering.Thanks to the lead-free soldering technology, AŽD Praha offers products meeting strict technical, safety and quality requirements with optimal im-pact on the quality of the environment. A pilot program aimed at the develop-

STRATEGY OF TECHNICAL DEVELOPMENT AND ENVIRONMENT

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ment and production of prototypes of new point machines (simplified LCA method) entitled “Impact of new products of AŽD Praha on the envi-ronment (process of development, manufacturing, operation and termination of product service life)” was implemented within the technical development project. The knowledge of stages in the product life cycle enables the marketing staff identifying impor-tant sources of negative environmental impact, which can be managed and systematically decreased.

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In 2004, energy audits were performed in the respective AŽD Praha plants in accordance with Act No. 406/2000 Coll. as amended. The outcomes of the audit identified possibilities of energy savings through no-cost measures with medium to long-term return. Windows were replaced in certain buildings of selected plants in Brno and Olomouc, and buildings in Logistic Plant Olomouc were provided thermal insulation. The system of heat recuperation was implemented in the manual and automatic paint shop of Production

Plant Olomouc. Heating of several AŽD Praha plants is procured by connection to the centralized heat supply. Logistic Plant Olomouc, the Division of Teleinformatics and the company headquarters in Prague have their own gas boiler rooms. The headquarters boiler room was equipped with a new equithermal regulation by Controlesta RCO system from ELESTA company.Thanks to eleven temperature sensors located throughout the building,

ENERGY SOURCES SAVE MONEY AND ENVIRONMENT

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31 748 31 541

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the system is able to precisely regulate heating in the manufacturing hall and offices on the basis of space temperature.Other buildings can be comfortably heated in this manner to the optimal temperature in a required time and space. All the outdated, energy demanding and noisy sources of pres-surized air for central distribution in production plants were replaced with a new type of compressor with lower input and lower consumption of lubricants. In this type of compressors, the condensate from dewatering is filtered to reduce the content of oil substances.

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AŽD Praha makes investment into modernization of manufacturing technologies in its production plants not only for the sake of performance growth but also in order to improve its image in the area of environment protection. The restructuring of manu-facturing operations means a significant economic asset.

Production Plant Olomouc specializes mainly in mechanical engineering. The investment in the past five years

amounted to CZK 33.2 million. A number of machining centers of MAZAK company (lathing and milling center, five-axis machining center, verti-cal machining center, turning center) resulted in an increase in productivity of machining operations, improvement of the working environment (reducing noise and vibration), but is also ben-eficial for reducing the environmental risks, such as complete elimination of spatter of cutting fluid, lower volume of hydraulic fluid in the centers and their

PRODUCTION AREA

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own cutting fluid, extended period for working fluid exchange, etc.Thanks to opening of such machining centers, outdated machines could be decommissioned. In the area of metal processing, the installation of new CNC table shear and CNC press brake minimized the effects of vibration and the risk of possible leakage of hydraulic fluid.

Within the restructuring of manufac-turing operations, Production Plant Olomouc adopted the production of electrical boxes. Modern machinery is used for the production (TruPunch press brake with reduced vibration and noise, electric brake SAFAN E-Brake 150 – absence of hazardous hydraulics). The finishing of boxes is carried out through cooperation.

Production Plant Brno specializes particularly in electrical engineering (direct electronic assemblies). Modern production (clean workspaces) with a team of highly skilled staff can handle PCB populating with outlet compo-nents to through openings (manual), one-sided and double-sided populat-ing of PCB with SMD components (automated), combined PCB populating

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(outlet components + one-sided and double-sided SMD), wave soldering with a lead-free and lead-based solder in a protective nitrogen atmosphere, stencil-free application of solder paste/

glue by jet printing, reflow soldering of lead-free

and leaded sol-der paste in a protective nitrogen at-

mosphere, hand soldering with lead-free and leaded alloy, AOI of populating and

soldering of the SMD component, automatic

in-circuit test of PCB assembly, mounting structural elements to PCB,

commissioning, testing and burn-in of electronic assemblies. However, even such state of the art technologies can-not do without a responsible approach to the environment.

Production Plant Brno has recently modernized its finishing operations acquiring the new DRY CLEAN OPEN spraying booth equipped with three-stage filtering including the final stage with activated carbon. Completion of development and launching

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the production of a new line of DT 075 transformers represents another benefit for the environment. These transformers work without conventional oil filling, which presented a risk of contamination of gravel ballast of the track superstruc-ture in case of emergency situations (railway accidents).

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Supplying production plants with material, transport of products to the logistics center and supplying con-struction sites is procured by a modern fleet of Logistic Plant Olomouc which always complies with mandatory emis-sion limits. Specialized machinery is continuously modernized (truck cranes, excavators and other small machinery with combustion engines) in order to meet strict European emission limits.

LOGISTICS AND ASSEMBLY WORK

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Replacement of concrete products with products made of recycled plastic is an important contribution of AŽD Praha to the protection of mineral resources (gravel, stone, limestone), reducing energy consumption inherent to the extraction of raw materials, energy-intensive cement production as well as to reducing transport costs. At present, 22 types of products are manufactured from the recycled plastic, used in the wayside equipment, installed

together with external components of the signaling systems which are

part of the AŽD Praha produc-tion program. Our company

participates in the develop-ment of the plastic products in

cooperation with MOSEV plast company. Products made from recycled materials have signifi-cantly lower weight, which reduces the physical effort of construction workers on building sites.

RECYCLED PLASTIC TO REPLACE CONCRETE PRODUCTS

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WASTE MANAGEMENT

The system of consistent waste separation into labeled containers was introduced as part of the waste man-agement program. Besides separating waste in the production plants, it is also separated on construction sites during assembly performed by our units and departments.All waste produced is handed over to certified companies and the waste management process is properly recorded in SW EVI8 on the intranet. The AŽD Praha plants in the respec-

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of construction and assembly work on construction sites, in particular the emergence of construction waste during the implementation of landscap-ing in connection with ground works.

tive regions observe the “Waste Management Plans”. The following goals are included in the AŽD Praha Waste Management Plans:

• reducing specific waste production,• minimizing negative impacts on

human health and the environment,• separation of municipal waste with

special attention to hazardous waste,• consistent application of recollection

of used products• reducing the proportion of waste for

landfill disposal (giving preference to recycling and energy recovery)

• increasing the proportion of internal returnable packaging.

Large investment was made into designing the system of waste separa-tion (containers) and of due storage of the waste until the handover to certified companies for disposal. A new waste management structure was built in the premises of Production Plant Olomouc and special certified mobile containers with a sump tray are used for temporary waste storage. Mobile containers are primarily used on construction sites, but also in the prem-ises of our plants. Waste production is influenced by both the volume of industrial production and the nature

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WATER PROTECTIONAŽD Praha also operates technologies (degreasing surfaces prior to surface treatment, galvanizing, paint spraying etc.) that require a lot of input water and which produce industrial waste water. The waste water is treated in our own waste water treatment plants (neu-tralization stations in the production plants in Brno, Olomouc and Prague) to keep the pollution level under the limits permitted by the decision of the respec-tive local water management authority before discharging the waste water into sewerage system. There are other substances dangerous to water used in production plants (CHLaS), which have to be stored in a due manner.

Storehouses are regularly inspected for water tightness. The handling of water pollutants is regulated by the “Plan of Action in Case of Accidental Degradation of Water Quality” in the respective AŽD Praha plants, which includes provision of emergency resources for the primary remedial intervention.

In case of handling water pollutants during assembly operations in line structures, attention must be paid to conditions prescribed by the compe-

tent water management authority within approval of construction docu-ments, in particular with respect to water protection zones, and protec-tion of nature and landscape.

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The new Act No. 201/2012 Coll. on Air Protection, with the subsequent implementation decree No. 415/2012 on the permitted levels of pollution and their measurement and on the imple-mentation of certain other provisions of Act on Air Protection came into effect on 1 September 2012. Selected opera-tions and technologies of AŽD Praha are classified under Annex No. 2 to Act No. 201/2012 Coll. as “Listed stationary sources or sources not mentioned / not listed”.All the sources of pollution are duly registered and they are inspected in order to operate in compliance with the legislation.

The selected sources of pollution are measured by authorized measuring groups within required periods.When upgrading machine and manual paint shop in Production Plant Olomouc, the system was equipped with carbon filters for capturing volatile organic compounds (VOC) in addition to filters for solid particles. The new recuperation unit in the manual paint shop leads to significant energy savings on heat from the centralized supply.

AIR PROTECTION

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and responsible approach to nature and landscape. Consistent application of all decisions of state administration in the area of nature and landscape protection is a necessary prerequisite for all construction projects. The decisions form an inseparable part of the building permit or of the environment section in the tender documentation, comprised in the implementation documentation of structures. A considerate approach to landscape is particularly important in line structures (cable routes, movement of machinery, etc.).

NATURE AND LANDSCAPE PROTECTION

Due to possibilities in the respective AŽD Praha plants and divisions, green areas are to be found only in the premises of Logistic Plant Olomouc. Exemplary care of the green areas created a pleasant environment in the vicinity of the plant. Cramped conditions in the premises of the other organizational units do not allow for lawn and planting. Complex situations frequently arise for assembly plants that work on construction of rail-way corridors passing through protected landscape areas, natural monuments, bird sanctuaries, etc., which require specific

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In order to comply with statutory obliga-tions, AŽD Praha performed the physical assessment of relevance of requirements contained in Act No. 167/2008 Coll., Government Order No. 295/2011 Coll. and Methodological Instructions of the Ministry of Environment in all of its plants (organizational units, headquarters and two selected structures: railway station Stará Paka and railway station Přerov).

All the final reports have shown that under Section 14 Act No. 167/2008 Coll., AŽD Praha is not obliged to procure a financial security for covering potential preventive or remedial measures in the event of environmental damage in any of its plants.

PREVENTION OF ENVIRONMENTAL DAMAGE – ACT NO. 167/2008 COLL., AS AMENDED

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