TAP-YTL

          The Transatlantic Program-Young Technology Leaders (TAP- YTL) is a program hosted by the German American Chamber of Commerce(GACCom). Each year, 12 individuals from the United States are selected to explore an aspect of German business that would give them further insight into their field of study. The 2013 theme just happens to be Sustainable Manufacturing, how perfect! This 8-day intensive program will focus on innovative progress, including plant tours and briefings with industry experts. I am beyond excited about this wonderful and exciting opportunity! I know I will meet some great people on the trip, along with so much information my brain might burst. :)

Check it out!

Post-Trip Recap:

        I am now the President of the 2013 TAP-YTL: Sustainable Manufacturing delegation! My face and title can be viewed here. My responsibilities include creating a social media group so we can all stay in touch (Yay, Facebook group!) and also writing in the TAP-YTL Alumni Newsletter. I'm currently working on the Welcome Address for the newsletter. I also get to work with the other delegation presidents on organizing the Alumni Reunion. Clearly, this program has been an amazing experience so far, and I'm sure that will continue. To read the blogpost where I discussed the members and overall experience of those wonderful eight days with the delegation, visit here.

Thoughts on the Companies:

          Overally, the delegation visited seven companies, one institution, and one university. All this in eight days?!? Yes! Including a day trip to Cologne! Below, are some general information and my personal opinion of each of the companies we visited. You can click on each heading to be taken to the company's website. Most of the general information is word-for-word from the company profiles packet given to me by the TAP-YTL program.

        EOS E-Manufacturing: 

Dresden Frauenkirche made by EOS 

                  EOS is a solutions provider and a world leader in laser-sintering systems. These systems can be used to create anything from consumer goods to industrial components...everything laser-sintered directly from electronic data; therefore, they can produce highly complex shapes with one machine. As of now, this is limited to maybe the size of your classic college mini-fridge, but this is still quite impressive! All you need is electronic data (via CAD-drawing for example) and then out can come your product, in some sort of metal or plastic. My mind was blown!
                  I truly appreciated the morale of the company. They will not give their products to companies interested in making weapons or advancing women-trafficking/prostitution with their systems.

                  The systems function with a CAD model or some sort of software that enters code into the EOS machine. Sections of the layer of plastic powder are melted to form the desired shape, and then that section is lowered. This step is repeated until the shape is finished, and then the remaining plastic powder is brushed off. Each company EOS sells to are screened so EOS knows exactly what their process is being used for. EOS helps companies use the product and offers other services, but they do not disclose how the machine works. They will also not sell to companies who do not take safety seriously, as the powder is highly reactive and can enter the bloodstream upon skin contact.

in front of EOS machine

                   In terms of sustainability, the company focuses on the Triple Bottom Line (TBL) of social, ecological, and economical impacts. The four main sectors they focus on are suppliers, the EOS process, systems and solutions, and customers. The look at the entire life cycle through this analysis, categorizing suppliers and customers with either an A, B, or C rating which is dependent on the TBL. The company itself has public bikes, a relax room (for power naps), and company cars. Their new building will include a fitness center; therefore, employee health is also a priority. Hopefully, this can also decline the burnout period for upper management...something I feel the US (or even college students) struggle with today. EOS uses an integrated heating system of groundwater and energy from the process for heating and cooling. There is also a recycling company for their customers that will pick up and recycle old/used powder.
                 Overall, I found EOS to have an impressive product and a bold mindset toward sustainability and  how to manage the TBL.

         Ulrich Müller GMBH:
                 
                  This company focuses on energy optimization with ventilation, refrigeration and air-conditioning systems. The brand geff (generation efficiency) implements ecological responsibility and sustainable management of the planet's resources. Projects for BMW AG and Siemens AG were looked at closely on this trip.

BMW Welt 

                    BMW obviously produces automobiles and is very well-known in almost all parts of the world. At least in America, (and in my opinion) owning a BMW is quite classy. The manufacturing facility has solar panels on the side of the building, more for marketing, along with plants on a roof that is clearly visible from the windows as you walk along the factory tour. Everyday, about 1,000 body parts for cars are made. So far, BMW has reduced around 30% of its energy use by focusing on air handling, cooling, and heat recovery. Wastewater is an area of high expense, so the company is also focusing on reducing this amount through recovery and reuse processes. Nobody loses their job because of more energy efficient machines. Employees are simply retrained for another position within the company. 95% of the welding is now done by machines. 95% of the assembly line, however, is still run by people.

Siemens AG 

Siemens AG 

     



            The Siemens project was centered on renovating an old building in a shopping plaza to make it more energy efficient for future office space. While touring the building construction, I noticed the heavy insulation around every pipe. A lot of detail and apparently,it pays off. Siemens also has an intense monitoring system, so they know where and how the energy is being used. Very detailed and precise.
                     On a side note, it was Steffan Müller, the Managing Director for Ulrich Müller GMBH, who was our main speaker. Each delegation member had to bring a gift that symbolized their home, so I brought a VT football. Steffan was the lucky speaker recipient of my gift!

           






           Volkswagen Engine Plant:
                 
                   The program visited the plant in Chemnitz that mainly produces four-cylinder petrol and diesel engines. The company is a member of Umweltallianz Sachsen (environmental alliance for the Saxony region of Germany). They recently received 2009 Factory of the Year "outstanding innovation management" and 2011 Factory of the Year overall winner. Their goal is to reduce environmental effects by 25% by 2018, meaning 25% less water, solvent emissions, energy, wast, and carbon dioxide. Every plant has their own reduction goals, but each produces a joint commitment. Volkswagen focuses on the interaction between economic and ecological leadership, analyzing the entire life cycle of a vehicle. The energy efficiency strategy is called "Think Blue" and is based on society, efficiency, energy supply, and employees. This is a holistic approach, where they analyze energy, systems and methods, and planning concepts. Photovoltaic panels are used to provide renewable energy for the plant. Bicycles are provided inside the factory for workers to easily travel inside. Skylights are used to light the factory and well water used to cool plant.
                    A huge part of the Volkswagen strategy was employee education. Within the factory are several boards where the goals of the company are posted. There is a training center where the employees learn about energy sustainability. For example, there is a station dedicated to compressed air and where energy is lost (leaks, diameter, etc). Volkswagen even looks at light reflections on the ceilings and walls to optimize. Employees are also instructed on turning off machines when not in use and which machines not to turn off. There is also an incentive for employees to be innovative in how the company can reduce energy. Employees can send in suggestions and get a cut of profit if their suggestion is used.

          Bosch Rexroth:

              Bosch Rexroth specializes in drive and control technologies. They use their own products to produce 'green' products. Every worker is aware of the push for energy efficiency, and lights that reflect where the company stands with its goal. Corrective, preventive, and organization measures have been taken to optimize energy use. Skylights and wall insulation have been installed. The skylights also allow some air into the building, which apparently is good for fire safety. In order for the workers to understand the amount of energy being saved, the company provides energy savings in terms workers can relate to, such as energy required for ten family homes saved. The use of photovoltaic solar panels saves 270 tons of carbon dioxide each year. Labels reflect which machines in the factory are allowed to be turned off and how exactly to turn them on and off. the "Go Green" project will save 20% of carbon dioxide emissions by 2020; however, the company could reach this goal by the end of this year. In training the staff, the company tries to make it like the workplace is the employees' homes. On a side note, there were a lot of bunnies surrounding the factory. Since the area is fenced in, the bunnies have gathered without any predators. So many!

         Schmale Maschinenbau GMBH: 

                 Schmale develops and provides customized manufacturing systems for producing complex components with bend s or angles. They increase productivity and quality by designing one machine to do the work of multiple machines and employees. The company compared mechanic, servo-hydraulic, and hydro-mechanic machines to see which worked best in terms of changeover time, force, controlability, flexibility, and energy consumption. Hydro-mechanic was determined to be the best technology as of now and Schmale is the only company currently using this method. As a fun fact, Schmale is also the only German company to have a logo for energy efficiency.