Volkswagen Pune Plant is a ‘Think Blue. Factory'
Volkswagen Pune Plant, one of the 27 Volkswagen automotive manufacturing facilities worldwide, follows the ‘Think Blue. Factory.’ initiative to achieve environment-friendly manufacturing. Through this initiative, Volkswagen aims at reducing the impact of its manufacturing process on the environment by 25% per car globally through its participating facilities. While the programme was adopted by Volkswagen globally in 2011, Volkswagen Pune Plant has been working towards the goals since 2012. The impact on environment through manufacturing processes is measured across five key areas of ‘Energy Consumption’, ‘CO2 Emissions’, ‘Water Consumption’, ‘Waste Generation’ and ‘VOC Emissions’.
Published on: Mar 4, 2016
Transcripts - Volkswagen Pune Plant is a ‘Think Blue. Factory'
Volkswagen Pune Plant achieves its first ‘2018 target’ of
‘Think Blue. Factory.’ four years before time
30.5% reduction in specific ‘Waste Generation’ marks the first target achievement for
Volkswagen Pune Plant under the global environment-friendly manufacturing
initiative ‘Think Blue. Factory.’ undertaken by Volkswagen
With 21.2% reduction in specific ‘CO2 Emission’ and 20.6% reduction in specific
‘Energy Consumption’, Volkswagen Pune Plant on the verge of achieving its target
reduction in two more key areas of ‘Think Blue. Factory.’ very soon
Mr. Andreas Lauenroth, Executive Director – Technical, Volkswagen India Private
Limited and Head of Volkswagen Plant in Chakan said, “All the employees at
Volkswagen Pune Plant have undertaken ‘Think Blue. Factory.’ programme as a part
of their everyday working and lifestyle. With innovative and effective ideas from our
teams taking concrete shapes, we have been able to achieve some of our goals well
before the set timeline of 2018.”
February 2015 – Volkswagen Pune Plant, one of the 27 Volkswagen automotive
manufacturing facilities worldwide, follows the ‘Think Blue. Factory.’ initiative to achieve
environment-friendly manufacturing. Through this initiative, Volkswagen aims at reducing the
impact of its manufacturing process on the environment by 25% per car globally through its
participating facilities. While the programme was adopted by Volkswagen globally in 2011,
Volkswagen Pune Plant has been working towards the goals since 2012. The impact on
environment through manufacturing processes is measured across five key areas of ‘Energy
Consumption’, ‘CO2 Emissions’, ‘Water Consumption’, ‘Waste Generation’ and ‘VOC Emissions’.
Starting from 2012, Volkswagen Pune Plant has undertaken a number of projects in the direction
of environment-friendly manufacturing and successfully implemented them to record remarkable
results. Three years into the programme, the plant has already surpassed the set target in the
area of ‘Waste Generation’ and is close to achieving its targets in the areas of ‘CO2 Emissions’
and ‘Energy Consumption’. Rounding off the fruitful results of Volkswagen India was the
consistent progress shown in the area of ‘Water Consumption’.
‘Waste Generation’: Target achieved and surpassed!
Amongst the five key measurable areas, maximum reduction has been achieved in the area of
‘Waste Generation’. As compared to the base value of 2011, the Volkswagen Pune Plant has
been able to reduce specific ‘Waste Generation’ by 30.5% (8.1 kg/car in 2011 reduced to 5.63
kg/car at the end of 2014). The main measure contributing to this achievement was the recycling
of paint sludge. This reduction was achieved by cutting down the moisture content from paint
sludge through centrifuge and further recycling the paint sludge to produce primer as a by-
‘CO2 Emissions’ & ‘Energy Consumption’: Success around the corner!
Volkswagen Pune Plant has closed in on the targets of two more key areas of ‘CO2 Emissions’
and ‘Energy Consumption’ by the end of 2014. With specific reduction of 21.2% and 20.6% in
specific values respectively, the targets are around the corner and will be achieved well within
the defined timeframe of 2018. Maximum saving in ‘Energy Consumption’ and hence also in
‘CO2 Emissions’ has come through the optimisation of operation of ‘Air Supply Unit’ in the Paint
Shop where huge reduction in CNG consumption has been achieved. The annual saving through
this translates to approximately 2,943 MWh/a out of the total 3,741 MWh/a saving. The other
projects contributing to this total saving include optimisation of operation of utility equipment,
installation of ‘High Speed, Low Volume’ (HSLV) fans, optimisation of lighting equipment and
optimisation of ventilation. The positive side of all the activities undertaken at the plant is that
none of the activities have hampered the working conditions for the employees. In fact, activities
like installation of HSLV fans has improved the working conditions on the shop floor.
‘Water Consumption’: Inspiring results recorded
A reduction of 14.4% has been achieved by Volkswagen Pune Plant in the area of specific
‘Water Consumption’. The major contributors to this saving are through modifications made at
the shower test area in Assembly and optimising the process PDI car wash. Adding to these is the
saving achieved through activities undertaken in 2013 that have yielded results on a longer term
‘VOC (Volatile Organic Compounds) emissions’: The Way Forward
The fifth defined area under ‘Think Blue. Factory.’ initiative is that of ‘VOC Emissions’ which are
mainly derived from the Paint Shop. Various measures are being studied for reducing ‘VOC
Emissions’ and the best practices will be implemented in the coming years.
Mr. Andreas Lauenroth, Executive Director - Technical, Volkswagen India Private Limited, and
Head of Volkswagen Plant in Chakan said satisfied with the latest results, “At Volkswagen Pune
Plant, ‘Think Blue. Factory.’ has become a part of our lifestyle. Within three years of adopting the
programme, we have achieved a 17.3% reduction per car in the impact of manufacturing
processes on the environment. We are well on track to accomplish our set target by 2018 to
lower the environmental impact of our production processes.” He further added, “At Volkswagen,
we have a commitment towards environment just like we have towards engineering, innovation,
quality and safety. We will continue striving hard towards this and not only reach our goals but
will go on to surpass them.”
About ‘Think Blue’
‘Think Blue’ is more than just a concept or strategy. It is a holistic approach adopted by Volkswagen that
embodies the goal of creating environmentally friendly products and solutions, encouraging more eco-
conscious behaviour and contributing to a sustainable future. It’s about being more responsible on the
road and more environmentally conscious - not just in our cars, but everywhere, every day.
About ‘Think Blue. Factory.’
‘Think Blue. Factory.’ is an addition to the Volkswagen ‘Think Blue.’ portfolio including key measures in the
area of vehicle production. The program, which is concerned with efficiency improvements in production
and the expansion of environmentally aware energy supplies, addresses all employees at the plants.
About Volkswagen Group India: With its headquarters in Pune, Maharashtra, the Volkswagen Group is
represented by five passenger car brands in India: Audi, Lamborghini, Porsche, ŠKODA, and Volkswagen.
The Volkswagen Group has been present in India for the last 14 years and began its India journey with the
entry of the ŠKODA brand in 2001. The Audi brand and Volkswagen brand entered India in 2007, while
Porsche brand and Lamborghini brand followed in 2012. Each brand has its own character and operates
as an independent entity in the market. Volkswagen Group India has over 25 models in India and 262
dealerships and is operating through two plants – Pune and Aurangabad. The Pune Plant has a
manufacturing capacity of 130,000 cars per year (in current two-shift system) and is currently
manufacturing Volkswagen Polo and Vento and ŠKODA Rapid. The Aurangabad Plant caters to various
premium and luxury models of Audi, ŠKODA and Volkswagen sold in India and has an annual capacity of
approximately 89,000. Volkswagen Group India is a part of Volkswagen AG, which is globally
represented by 12 brands - Audi, Bentley, Bugatti, Ducati, Lamborghini, Porsche, Scania, SEAT, ŠKODA,
Volkswagen Commercial Vehicles (Volkswagen Nutzfahrzeuge), MAN and Volkswagen Passenger Cars.
Volkswagen Group India Communications
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Phone: +91-8554997356 / +91-7875557435
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