Updated Environmental Statement 2019 EvoBus …...2020/02/20 · policy and environmental impacts. the Environmental Statement is updated in the intervening years but only for updated

Updated Environmental Statement 2019EvoBus GmbHMannheim plant

2 UpdatEd EnvironMEntal StatEMEnt 2019

inhalt3 preface4 the EvoBus plant in Mannheim6 Energy and environmental program 12 Figures, data, facts26 validation

Imprint

Responsible environmental protection officer: randolf troche BUS/opt-UWS

Responsible editor:Stephan Schmitt BUS/opt-UWSEnvironmental protection departmentphone: +49 621 740-2127telefax: +49 711 17-790 [email protected]

Head of Production Daimler Buses:dr. Marcus nicolai

Layout and implementation:daimler aG, CBS/M

imprint allowed with exact source.

UpdatEd EnvironMEntal StatEMEnt 2019 3

preface

Dr. Marcus NicolaiHead of production daimler Buses

Randolf TrocheHead of environmental protectionMannheim plant

the Mannheim location stands for the development and production of city buses and thus makes a significant contribution to environmentally friendly urban mobility concepts. apart from the classic diesel-fueled Citaro, these also include gas-fueled buses, hybrid vehicles and, as of this year, our eCitaro as a fully battery-electric vehicle, which is thus free of local emissions. on the production side, we are currently implementing our production vision, based on which we will build city buses in Mannheim efficiently and in alignment with the basic idea of industry 4.0.

Since the start of 2019, environmental protection has been assigned to technical service at the Mannheim and neu-Ulm locations.

the environmental management system has a long tradition at the location though. Since 1997, annual external validation has been taking place – especially of the Environmental Statement in accordance with the European directive EMaS. in the EMaS register, EvoBus Mannheim can be found with the registration number dE-153-00022. the registration certificate is updated by the Chamber of industry and Commerce every three years. this took place most recently in 2018. this is done by submitting the Environmental Statement, including the topics of environmental policy and environmental impacts. the Environmental Statement is updated in the intervening years but only for updated topics. the certification of the international environmental management standard iSo 14001 has been integrated into the matrix certification of our production locations since 2015.

Mannheim, May 2019


the EvoBus plant in Mannheim


tradition meets modernityapart from city bus construction, bodies-in-white for touring coaches and inter-city buses are also manufactured at the EvoBus GmbH location in Mannheim. the portfolio of the Citaro city bus family covers a large product range of non-articulated and articulated buses that are fueled by diesel, gas and electricity. the first battery-electric buses were handed over to customers at the end of 2018.

the entire plant floor space comprises 305,656 m2, of which 130,100 m2 is sealed as development space and 128.603 m2 is sealed as a traffic area. on the location premises, 16,591 m2 is left in a semi-natural state. outside the location, no semi-natural spaces are managed by EvoBus. the display of the core indicator “land consumption in relation to biological diversity” is depicted on page 21; this is limited to sealed spaces from development and asphalting.

at the end of 2018, 3,436 employees were employed. this number includes interns, diploma students and trainees.

Compliance with legal provisions, official requirements and other mandatory requirements is a matter of course for our company. For this purpose, the required information and resources for reviewing and achieving the requirements are ensured.

Plan of the EvoBus plant in Mannheim in 2018

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Energy and environmental program


in our energy and environmental program for the Mannheim plant, the most important targets of the individual units are taken from their energy and environmental program and summarized. on this page, the location’s environmental program for 2019 is presented with the completion Status.

on the following pages, you can find the current energy and environmental program, including selected targets of our plant, with the respective responsibilities and the target completion date.

Goals for 2018 Measure Assessment criterion Planned date

Completion status*

Process optimization

reduction of environ-mental impact

Contribution to daimler target 70 % of the supplier revenue (purchased parts) is covered by certificates for environmental management

Evaluation criterion of at least 70 % has been met

04/19 done, ongoing issue

reduction of hazardous material use and emissions

Conversion relocation of the raised floor Floor coating to neu-Ulm

implemented 06/18 done

Energy saving

reduction of energy consumption

implementation of the “Switching off machines outside working hours” project

the machines that may be switched off have been defined and labeled

06/18 postponed until decem-ber 2020


replacement of the Cdp dryer’s thermal afterburning

planning, notification/approval, and installation of the Cdp dryer’s new thermal afterburning. Energy conservation

02/18 done


renewal of the ultrafiltration in Cdp proof of energy conservation 06/18 done

Efficient processes

reduction of energy consumption and chemicals

the tube washing unit was replaced with a tube cleaning unit. the cleaning is done by means of a foam plug that is shot through the tube with compressed air

the tube washing unit is no longer in service

10/18 done

Using substitutes for hazardous materials

Conversion of the floor coating to black for the Citaro

Converted 01/18 done

Using substitutes for hazardous materials

Substitution of black (zinc-free) for Cdp paint Substitution started after authori-zation by the regierungspräsidium (regional administrative council)

06/18 done

reduction of noise development

Expansion of natural gas filling station reduction of compressor run times per vehicle

06/18 done

reduction of environmental impact

Changing the assembly process in order to reduce reworking due to damage

Changed assembly sequence for glazing and painted external parts

12/19 taken over in 2019

avoidance of packaging materials

incorporation of Mercedes-Benz turkey in production network with standard load carriers

Use of standard load carriers and gradual elimination of one-way wood and cardboard packaging

06/19 taken over in 2019

Energy and environmental goals for 2018

* Status: april 15, 2019


Energy and environmental goals for 2019


Primary res-ponsibility

Process optimization

reduction of Co₂ emissions

derivation from green production for the location: reduction of absolute Co₂ emissions in Europe

By 40 % by 2030 (base year 1992–94)

12/30 BUS / oM


Contribution to daimler target of having 70 % of supplier revenue (purchased parts) be covered by certificates for environmental management

annual pursuit of measures 04/19 tp / G52


reduction of wax application of the materials cur-rently used in B32 as a consequence of the use of black floor coating

Specification created in accordance with the floor coating changeover and implementation coordinated with the unit. reduction of the kg/vehicle is to be taken from the guideline values

07/19 CQW

Energy saving


derivation from green production for the location: reduction of global energy demand

By 2.5 % per vehicle per year by 2030 (base year 2013–14)

12/30 BUS / oM


reduction of the combustion chamber temperature of Cdp-tnv following documentation of compliance with limit values through measurement and public authority confirmation

reduction of the combustion chamber temperature from 745 °C to 725 °C

05/19 oMB


implementation of the “Switching off machines outside working hours” project

Machines that can be switched off are defined and marked

12/20 opt


Conversion of office lighting to lEd in Building 135, rooms 101–103, and Building 45, rooms 201–205

Calculated saving approx. 4,000 kWh/a

03/19 oMB


Continuation energy and environmental goals for 2019


Primary res-ponsibility

Efficient processes

increasing recycling rate

derivation from green production for the location: increasing the global recycling rate and objective: „Zero waste to landfill“

to 90 - 95 %; -2.5 % per vehicle per year by 2030 Waste for disposal (base year 2013–14)

12/30 BUS / oM

Conservation of resources

reduction of grab bar waste parts, waste optimiza-tion, and fewer mistakes when making cutouts by using a new laser system

assessment as to whether there are fewer complaints and duplicate productions

06/19 oMM

Conservation of resources

Use of smart repair in the finish area reduced use of solvents 12/19 oMM

reduction of paper use reduction of accompanying vehicle papers by using pda

Using pda yes/no 10/19 oMM

avoiding packaging incorporation of Mercedes-Benz turkey into the production networkrnwith standard load carriers

implementation of standard load carriers and gradual elimination of single-use wood and cardboard packaging

06/19 oSl


Changing the assembly process to reduce reworking due to damage

Changed assembly sequence for glazing and painted external parts

12/19 opl

reduction of masking scopes in the floor coating area on the front + rear

reduction of masking scopes in the work schedules documentation of eliminated masking scopes

04/19 oMB




Figures, data, facts


production

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2016 2017 2018Manufacturing units (MU) Body-in-white MU for sister plants PU (production unit) equivalents

Production figures

Mannheim is the main production location of the Mercedes-Benz Citaro city bus fleet for public transportation. in addition, all bodies-in-white of the Mercedes-Benz and Setra brands are produced here for assembly at sister plants in neu-Ulm and ligny-en-Barrois (France).

in 2018, 2,107 fully-equipped buses were assembled at the Mannheim location, which corresponds to 2,766 manufacturing units [MUs]. the plant also prepared the bodies-in-white for 7,952 MUs. the number of manufacturing units is higher because an articulated bus consists of two manufacturing units.

the calculation of production unit [pU] equivalents takes into account the amount of work done in all plants participating in the production network. Since the introduction of this key figure in 2012, the value has leveled out at between 2,000 and 3,000 pU equivalents.


Emissions

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2014 2015 2016 2017 2018VOCs in g/m₂ of surface to be painted per vehicle Proportion due to Mannheim plant Proportion due to Neu-Ulm plant

VOC figures

Solventthe emissions of solvents overwhelmingly occur as a result of surface coatings. the solvent emissions in Mannheim have decreased consid- erably since 2011, when the vehicle topcoat painting process was transferred to the plant in neu-Ulm. the use of solvents, measured in voC per square meter, is significantly lower than the legally prescribed limit value of 150 g per square meter and is thus at a good level.

in 2018, the calculation of the voC value was revised; it was updated on the basis of the sampling of old paints, the efficiency measurement and the vehicle surfaces.

Noisein 2018, there was a production-related noise complaint by a local resident. Measures were promptly implemented in response to this; compliance with these measures is ensured.

Greenhouse gasesthe greenhouse gases that are emitted by the technical systems at our Mannheim plant are mainly due to the use of natural gas as one of the primary energy sources. in 2018, 2,081 metric tons of greenhouse gases were emitted; this corresponds to a 14.0% increase compared to the previous year.

With the exception of one occasion where the carbon monoxide limit value was exceeded, there were no further anomalies in the Cdp-tnv unit in 2018. When the carbon monoxide limit value was exceeded, we responded with immediate measures so that compliance with the limit value could be guaranteed again.

the precise figures for greenhouse gas emissions from our plant can be found in the list of core indicators on page 23.


Energy

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2014 2015 2016 2017 2018Consumption [GWh] Consumption per PU equivalent [MWh]

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2014 2015 2016 2017 2018Consumption [GWh] Consuption per PU equivalent [MWh]

Electricity consumption Natural gas consumption

the following diagrams depict the energy consumption, broken down by the main energy sources. the consumption of heating oil is not represented here, because it is a negligible energy source, accounting for less than 0.5% of the total energy consumption. the heating oil consumption is taken into account when calculating the total energy consumption. the absolute energy consumption of the last three years at the Mannheim location is shown on page 21.

Electricity the diagram below shows the plant‘s electricity consumption from 2014 to 2018. For 2018, this amounts to 29.3 GWh and is thus higher than the previous year by approx. 7.7 %. this increase can be traced back to increased production figures. Consumption per manufacturing unit equivalent has decreased by 1.5 % to 10.1 MWh.

Natural gasthe natural gas consumption for 2018 amounts to 10.7 GWh and is thus 8.3 % higher than in 2017. However, per manufacturing unit equivalent, it was reduced by 0.3 % to 3.7 MWh.


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2014 2015 2016 2017 2018Consumption [GWh] Consumption per degree day [MWh]

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2014 2015 2016 2017 2018Volume [10³ m₃] Volume per PU equivalent [m₃]

District heating consumption Total water consumption

District heating the heat consumption is displayed for the third energy source. this is additionally related to the degree days at the location. the relation to the degree days is necessary because the heating requirement depends heavily on the weather conditions, and this is the only way to enable a meaningful comparison with the previous years.

Compared to the previous year, consumption, both in absolute and relative terns per degree day, increased by around 0.5 % and is approxi-mately at the level of 2014 with 27.7 GWh or 10.1 MWh per degree day. this can be traced back to the increased production program and the resulting increased hall usage time.


Water

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Well water consumption Water from public utilities

in order to document our water consumption figures, we first calculated the total consumption of freshwater. overall, demand has increased compared to 2017, both in terms of the total amount consumed and the amount per production unit equivalent. the total water consumption of 135,925 m3 in 2018 consists 82 % of well water and 18 % of drinking water. the consumption of well water and water from public utilities is depicted on the following page.

Well waterthe well water used in the plant is drawn by daimler aG from wells at the location, and it is used exclusively for production. the diagram in the bottom left corner shows that the amount drawn in 2018 increased by 19 % from 93,242 m3 to 110,972 m3 compared to the previous year. Consequently, the amount per production unit equivalent also increased by 9.1 % from 35.1 m3 to 38.3 m3. the increased demand for well water is, on the one hand, a consequence of increased production figures and, on the other, a consequence of the high temperatures during the summer months, which meant the cooling systems were used more intensively.

the process cannot be broken down further because the monitoring system shows only the total consumption of the plant. With the current monitoring system, it is not possible to assign consumption values to the individual stages of production. We are planning to improve the trans- parency of the monitoring process so that we can assign specific consumption figures.

Water from public utilitiesthis representation of water consumption figures refers to the consump-tion of drinking water (primarily for the sanitary facilities) provided by public utilities. in 2018, the drinking water production decreased by around 6.1 % to 24,953 m3 compared to the previous year. in terms of the production unit equivalents, consumption was also reduced by 13.7 % to 8.62 m3 per pU.


Waste water

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2014 2015 2016 2017 2018Total wastewater [10³ m₃] Treated wastewater [10³ m₃] Evaporated volume [10³ m₃]Wastewater from sanitary facilities [10³ m₃] Wastewater per PU equivalent [m₃] Treated wastewater per PU equivalent [m₃]

Wastewater development

Waste water is, on the one hand, dependent on production and, on the other, a base load in the production facilities, supplemented with a certain amount from the sanitary areas. the total amount is calculated by taking the freshwater consumption and subtracting the volume of water that has been calculated but not discharged. the waste water value in 2018, subject to the increased fresh water consumption compared to 2017, also increased significantly.

the waste water discharges occur exclusively into the municipal sew-erage system and are subject to continuous monitoring as an indirect discharge. thus, again in 2018, the discharge points were regularly tested by the municipal waste water system of the city of Mannheim. Based on this sampling, the city imposed a surcharge based on the parameters of the total nitrogen bound, phosphorus (tp), and the total organic carbon (toC) in accordance with the waste water regulations.

the waste water from the cathodic dip painting process (Cdp), the portal unit for surface treatment (pUSt), the pretreatment for the powder unit and the bus leakage test are tested in accordance with the applicable self-monitoring guideline for the state of Baden-Württemberg.

in 2018, the limit value was not exceeded at all during external waste water investigations.

the plant regularly shares information with the responsible authorities. determined limit value violations are communicated to them, but, if necessary, solutions to problems are also striven for, defined and implemented together.


Waste

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2014 2015 2016 2017 2018Total [t] Recycled [t] of which, scrap metal [t] Disposed of [t]

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2014 2015 2016 2017 2018Waste recycled per PU equivalent [kg] Waste disposed of per PU equivalent [kg]

Production waste development Proportion of waste recycled/disposed of

Production wasteWaste is recycled or disposed of under the waste generator number of EvoBus GmbH Mannheim. the technical process has been conducted since 2016 at the disposal center on the premises of EvoBus GmbH.

the total volume of production waste was 6,352 metric tons in 2018, which represents an increase compared to the previous year. this increase can be traced back to higher body-in-white production, which is associated with a higher occurrence of scrap metal. the high percentage of scrap metal, amounting to 62.3 % or 3,956 metric tons, is characteristic of body-in-white production.

Recycling/disposala positive note is the fact that almost all of the total production waste, 99.7 %, to be exact, was recycled in 2018, the same proportion as in the previous year. a total of 6,336 metric tons were recycled, and 16 metric tons were disposed of.

Because the amount of waste for disposal has been very low since 2014, it is no longer represented in the diagram below.


transportation & external companies

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2014 2015 2016 2017 2018Body shipment by train [%]

Body transport (shipping)

TransportationSince 2016, we have been delivering bodies-in-white to our sister plant in neu-Ulm exclusively by train. Because of the greatly divergent transportation costs, we are continuing to deliver bodies-in-white to ligny-en-Barrois (France) by truck. in 2018, 85.6 % of these products were transported by train. the current record value of 89.4 % was reached in 2016.

We are continuously optimizing the filling levels of our load carriers for internal and external product deliveries.

the completed buses leave the plant on their own axles.

External companies on the plant site and inclusion of suppliersthe external companies that operate at our location are bound to con- tractual agreements. in addition, at least once a year, they attend an informational event at our location, where they recommit themselves to fulfill the requirements of our management system.


Core indicators according to EMaS iiithe amended EU directive EMaS iii requires us to evaluate our environmental performance.

We are expected to present the core indicators of our energy and materials efficiency, water consumption, waste generation, land consumption in relation to biological diversity, and emissions and to indicate the relationship between these core indicators and the plant’s overall output or value creation.

Energy consumption consists of the figures for electricity, natural gas, hot water and heating oil.

Based on the amendment of appendix iv of the EMaS directive, the production unit equivalents are selected as a new relationship indicator and thus replace the added vehicle-related and model-related mass of the vehicle deliveries and bodies-in-white shipped as a relationship indicator. a detailed representation of the environmental performance is enabled using this approach, as is the observance of special characteristics. the efficiencies of the core indicators for the years 2016 and 2017 were also updated with regard to the new production unit equivalent rela-tionship indicator.

the comparative development of the plant‘s environmental performance can be represented by means of the specific key figures and the core indicators we have used. Because of the unique nature of the activities at the location, no cross comparisons or sector comparisons are possible.

the core indicators are represented in a table on the following pages.

Year Ipsum 2016 2017 2018

production unit equivalents ¹ 2.572 2.638 2.885

Core indicator

Energy consumption absolute amount [MWh] 62.083 64.667 67.692

Efficiency [MWh/Stk] 24,14 24,51 23,46

proportion of energy from renewable sources ² absolute amount [MWh] 0 0 0

Mass flow input ³,⁴ absolute amount [t] 42.688 41.863 66.474

Efficiency [t/Stk] 16,60 15,87 23,04

Water consumption ⁵ absolute amount [m3] 124.763 119.814 135.925

Efficiency [m3/Stk] 48,51 45,42 47,11

land consumption in relation to biological diversity ⁶ absolute amount [m2] 267.808 258.703 258.703

Efficiency [m2/Stk] 104,12 98,07 89,67

Core indicators according to EMAS III – Input

¹ determined integral bus coordinated production system² no renewable energy is produced at the plant³ Sum of tonnage and production waste⁴ 2018 value using new calculation method⁵ total water consumption⁶ Sealed area due to buildings and asphalting


Core indicators according to EMAS III – Output Part 1

Year 2016 2017 2018

Equivalent unit of production ¹ 2.572 2.638 2.885

Core indicator

Mix of recyclable materials absolute amount [t] 1.052 986 958

Efficiency [t/Stk] 0,4090 0,3738 0,3321

Emulsions absolute amount [t] 294 341 268

Efficiency [t/Stk] 0,1143 0,1293 0,0929

Sludges from the plant’s wastewater treatment absolute amount [t] 258 271 298

Efficiency [t/Stk] 0,1003 0,1027 0,1033

other waste fractions < 200 t absolute amount [t] 729 585 873

Efficiency [t/Stk] 0,2834 0,2218 0,3026

Scrap metal absolute amount [t] 3.549 3.342 3.956

Efficiency [t/Stk] 1,3799 1,2669 1,3712

total amount of production waste absolute amount [t] 6.044 5.652 6.352

Efficiency [t/Stk] 2,3499 2,1425 2,2017

total amount of hazardous production waste absolute amount [t] 748 719 713

Efficiency [t/Stk] 0,2908 0,2726 0,2471

total amount of construction waste ⁷ absolute amount [t] 889 2.239 898

¹ determined integral bus coordinated production system ⁷ no calculation of efficiency


Core indicators according to EMAS III – Output Part 2

Year 2016 2017 2018

Equivalent unit of production ¹ 2.572 2.638 2.885

Core indicator

Greenhouse gas emissions ⁸ absolute amount [t] 1.933 1.825 2.081

Efficiency [t/Stk] 0,7516 0,6918 0,7213

pollutant emissions noX ⁹ absolute amount [t] 2.190 2.312 2.504

Efficiency [t/Stk] 0,8515 0,8764 0,8679

pollutant emissions So₂ ⁹ absolute amount [t] 310 158 187

Efficiency [t/Stk] 0,1205 0,0599 0,0648

pollutant emissions pM ⁹ absolute amount [t] 1.029 1.090 1.428

Efficiency [t/Stk] 0,4001 0,4132 0,4950

pollutant emissions voC ¹⁰ absolute amount [t] 67 72 62

Efficiency [t/Stk] 0,0260 0,0273 0,0215

¹ determined integral bus coordinated production system ⁸ Co₂ due to gas, heating oil, refills of refrigerants (new GWp conversion factors starting in 2016). Up to 2015, coolant with CH₄, n₂o from personnel and freight transport ⁹ due to natural gas and heating oil. Calculation according to GEMiS 4.2¹⁰ due to sealing of surface areas




validation


the undersigned, dipl.-Geol. Bernhard Schön, EMaS environment expert of tÜv SÜd Umwelt-gutachter GmbH with the registration number dE-v-0321, accredited or authorized for Unit 29 (naCE code) confirms that he has assessed whether the location, as published in the Environ-mental Statement 2019 of the organization EvoBus GmbH, Mannheim plant, with the registra-tion number dE-153-00022, fulfills all the requirements of the directive (EC) no. 1221/2009 of the European parliament and of the Council of november 25, 2009, and the directive (EU) 2017/1505 from august 28, 2017, concerning the voluntary participation of organizations in a shared system of environmental management and environmental audit measures (EMaS).

By signing this declaration, i confirm that

» the audit and the validation were conducted in full conformity with the requirements of directive (EC) no. 1221/2009 and directive (EU) 2017/1505,

» that the result of the audit and the validation confirms that there is no evidence of nonconformity with the applicable environmental regulations,

» and that the data and the content of the location‘s Environmental Statement provide a reliable and truthful picture of all of the activities of the location within the unit speci-fied in the Environmental Statement.

this declaration cannot be equated with an EMaS registration. the EMaS registration can be completed only by a competent authority in accordance with directive (EC) no. 1221/2009 and directive (EU) 2017/1505. this declaration must not be used as an independent basis for infor-ming the general public. the present Environmental Statement has been audited and declared valid.

Munich, May 31, 2019

Bernhard SchönEnvironmental verifierdE-v-0321

daimler aGMercedesstraße 13770327 Stuttgart Germanywww.daimler.com

Documents

Updated Environmental Statement 2019 EvoBus …...2020/02/20 · policy and environmental impacts. the Environmental Statement is updated in the intervening years but only for updated