World attention is now drawn to the global manufacturers of consumer products and the attention they pay to every aspect of a products lifecycle as well as its production, in terms of the impact that it has on the environment.
adidas AG recognised that if they were to have a sustainable, integrated approach to this problem then they would need new management tools.
The project objective was to develop the methodology, strategies and procedures that would effectively monitor the ‘life-cycle’ of a consumer product, and implement the solution with an aim to reduce environmental impact.
Together with adidas we conducted an intensive research project that analysed the application of our integrated product policy (IPP).
As a result of this work we were able to establish new insights into the world-wide sourcing and life-cycle of the examined product, with hard facts that can now form the basis for making future decisions and realising improvements.
IPP is a win-win situation for manufacturers, suppliers and consumers.
A need for adidas AG had materialised with the chemical safety of the products.
Organisations for consumer protection began testing products from the market concerning their chemical safety and issued the results in magazines and on the internet.
To enhance the chemical safety of the products, a very complex instrument of testing procedures, controlling measures and certification was installed, which is now mandatory for all the suppliers.
Increased chemical safety of the products • Decreased the probability of rejected shipments by customs authorities of the selling markets (e.g. one rejected shipment in a key market can cost the company hundred of thousands of Euros). • Across the line the company was able to reduce testing costs by increased product safety. • A positive stakeholder image
In the mid 90’s there was serious concern from NGO’s about the environmental, health and safety conditions in the factories used by adidas AG, there was also concerns from consumer protection agencies, about the chemical safety of the products themselves.
Although adidas did not own these factories, it was felt that as they used them for the manufacturing of their sporting goods, they should take responsibility for their management, product safety and sustainability.
In conjunction with adidas, we developed a number of in-depth guidelines addressing the best practice requirements for health, safety, environmental and quality topics.
These guidelines were distributed and implemented in all factories. Some of these became mandatory requirements for the contracts of the factories. With regards to increasing the safety of the products, a very complex instrument of testing procedures, controlling measures and certificates for materials and products was installed which also became mandatory for all suppliers.
The guidelines we formulated were very easy and quick to implement and understand, and as a result, factory accidents were significantly reduced, product safety increased and the likelihood of product rejection by customs, reduced.
Testing costs on all products were also reduced due to the increase in chemical safety.
The overall results from what we had developed with adidas built a strong platform for their sustainability reporting and what had been negative press, now became positive.
Production-related waste is generated - for waste generators, it is essential to ensure a legally proper disposal of their waste. On the other hand both, processes and costs for waste management, should be optimised on a continuous basis.
Intechnica helped to improve their operational waste management through a comprehensive inventory analysis:
Query of waste data over a period of time
Specific on-site assessment regarding
Separation / segregation
Collection and disposal cycles
Collection points and containers
Transportation routes between point of origin and collection point
Evaluation / analysis / review of data
Check against legal requirements
Compilation of the results
Presentation of optimisation potential
For most companies waste management is no core business. Personnel capacity is limited and legal requirements are complex with a permanent need to be updated.
With our service the clients can:
Concentrate on their core business
Guarantee that the best knowledge and expertise is available
In the early 1990's, the Bavarian Environmental Ministry found that in all their different branches, they needed to improve their environmental performance. They asked Intechnica to develop guidelines for environmentally friendly production and economic and ecological processes for running their businesses.
Intechnica developed guidelines for diverse branches such as: - Breweries - Printing industry - Clothing and textiles industry - Diary industry - Sport clubs - Hospitals - Environmental management system for city governments.
In all those guidelines for the relevant branches, the environmental relevance of all the processes is highlighted, along with numerous examples for improvement, with calculations for potential savings on consumption and financial evaluation. They (the guidelines) are a comprehensive evaluation for all environmental aspects such as – energy, water, waste material and even organisational aspects in the running of management systems.
We have been conducting internal environmental audits at Dr. Ing. h.c. F. Porsche AG since 2003. They recognised the need to understand more about the individual relevance of legal compliance in accordance to the environmental aspects of each of their processes. The target was to develop a list of plants, machines and dealership locations, and evaluate their environmental performance.
The creation of an evaluation system, which assigns specific classifications (A, B, C, D) to all processes via lump sum numbers. To date this has been designed to assess each performance aspect of every machine and system in nearly 1,000 locations. The evaluation aspects include:
Heating energy consumption
Waste and protection of ground & ground water
Dr. Ing. h.c. F. Porsche AG now has a clear advantage by having much more than the standard evaluation criteria specified to hold the EMAS certificate.
Our evaluation system is actualised annually to retain clarity; it enables them to know the exact performance of each single aspect of every machine. All department heads now hold a complete list of specific classifications for all processes; from this, a programme for improvement can easily be developed.
High Energy consumption and rationalisation of a tennis ball factory in Manila.
An intensive survey of the factory’s energy production and consumption
Steam & hot water boilers
Air conditioning & ventilation
Production processes and materials
Developed many systems for change and improvement as well as an investment versus savings calculation.
Significant savings from implementing changes with a new investment in production processes and changes in energy production and consumption – cost £500,000, a complete return in Year 1 and significant ROI in subsequent years.
The software house and media consultant infowerk ag was required by its clients to demonstrate an internal Quality Management System. The system had to be installed in a very short time. Further, it was desired to provide a system for practical use by employees.
Together with infowerk ag, Intechnica developed a made-to-measure system which provides much more than the compliance to the ISO 9001 standard. The structure was derived from the infowerk processes and not from the ISO 9001 chapters. The system is a proprietary, self developed software, which avoids any confusion and additional work – a well known strain in systems written with MS Office.
The system could be implemented within 5 months and was highly accepted by the employees from the very first. After demonstrating the system to one of the key customers, they realised that there was no longer any need for customer audits. With the implementation of the developed software, the daily use of the system is much easier and return on invest was less than 6 months.
As one of the largest producers of wires, cables and wiring systems in the world. It became essential for Leoni AG to be up-to-date with continual changes in environmental legislation and relevant legal requirements.
Maintain updated legal registers
Interpret complex legal changes
Annual compliance audits
Preventative measures in place
Implementation of environmental management systems
On-going training/workshops (Environmental Management Systems & Protection of Executives)
Internal awareness of legal compliance, risk and occupational health & safety strengthened
Legal requirements of International Standards outsourced
The Control and minimisation of toxicity of raw materials in grain milling indutry. Problems exist such as mycotoxins, acrylamide and pesticides, with testing and analysis slow and cost intensive as well as interrupting the flour process.
Research into toxin levels in cereals
Development of Risk Management System
Development and implementation of guidelines
Development of IT tool for food analysis & traceability
Quick, easy, reliable and cost-effective detection of contaminants.
Improved risk management system
securing of all relevant legal requirements on food safety
Free support for system building through Intechnica
Use of instruments to improve product and manufacturing quality
Increased market credibility with certificates - legal certainty from established systems
Schneider Electric Sachsenwerk GmbH – Responsibilites of Managers in Environment, Health and Safety
To be well-informed and up-to-date in the different fields of national law as well as having a clear understanding of the requirements in international law, is not easy for managers; Schneider Electric recognised the importance of this for their management.
Because our consultants are in touch with the latest developments we could assign a team of experts to give a clear overview about the actual changes and any new developments that were about to become law.
expert knowledge in specific and relevant fields
up-to-date and informed about actual developments of laws
being aware of the potential future impact of changes in law
staying legally compliant within the whole company
A desire from internal and external pressure was to develop a greener business in all stores of Tesco. It became essential to develop a worldwide programme for the environmental sustainability of their associate suppliers for textiles and clothing products across the globe.
We developed a “green factory guideline” which included the sustainable aspects of architecture, energy, water, waste, emissions, soil and groundwater for the business. As part of Tesco’s commitment to tackle climate change all employees were asked to “five pledges” to be greener.
We then held a “green factory guideline workshop” at their UK headquarters, with all of their global suppliers in attendance, to manage guideline implement across several stores. Subsequent workshops were held in Bangladesh, Sri Lanka and China.
A “tailor-made” environmental programme for Tesco suppliers to benchmark against all Tesco guideline requirements, and a worldwide support programme via implementation workshops, to improve their sustainable development.
Publishers Verlag Nurnberger Press appointed Intechnica to improve their environmental legal compliance and to create a system that would enable them to monitor and control their environmental costs. This provided a unique opportunity to demonstrate an environmental commitment to their stakeholders, so they asked Intechnica to recommend ways of communicating that positively, clearly and openly.
We established an effective environmental system, in accordance with the European EMAS standards and defined parameters that supported all of its relevant procedures and operations to enable accurate monitoring.
We have established a long-term partnership of support that continuously monitors the legal compliance of the established system and its environmental performance. With their strict adherence to EMAS the company has improved their Insurance rating and the specific environmental programmes that we created for them, has reduced costs significantly. As an example, Verlag Nurnberger Presse’s waste costs were more than €33,000 in 2003, these changed to returns of €14,000 by 2004.
Aumüller Druck GmbH & Co. KG Christian Aumüller (CEO)
"For more than 20 years we have cooperated intensely with Intechnica. The story started with a waste concept. The city of Regensburg didn’t want the responsibility of industrial waste disposal, therefore we were forced to work on this topic systematically.
Starting with the waste concept; an integrated concept for environmental protection has been developed. Intechnica advised on the implementation of the Eco-Audit system and a successful validation was realised as early as1996. We became only the third EMAS-registered printing company in Europe.
Meanwhile Intechnica consults all divisions in Environmental protection and Health and Safety. We think it is amazing that we continually develop and improve due to our long-lasting cooperation. Intechnica is our engine, trusted advisor and auxiliary in this process."
"In subsequent years we have become interested in the topics of Health and Safety and Environmental Protection, in connection with our management system.
Intechnica has given us expert consultation in all of these topics to successfully certify our EHS system. In addition in 2014, our TQM met all of the ambitious requirements of EMAS.
We congratulate our partners Intechnica, on their 25th anniversary and look forward to corporately reaching new milestones in our management system."