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Efficiency

Efficiency


Efficiency may be described as the ability to achieve a desired effect with the minimum possible resources. In an increasingly complex and competitive world, we can only ensure the profitable growth of our organization by doing things better.

Efficiency model


Within the framework of the current Strategic Plan 2019-20121 Gonvarri Industries, Efficiency axis is reinforcing its systems of continuous improvement systems and its Core knowledge management through actions coordinated by SGI (Integrated Management System, the result of the merger of the Health and Safety, Environment, Quality and SPG/Lean Manufacturing areas) and BTM (Business Technology Management).

Integrated SGI Audit


Created in 2017, the Integrated SGI Audit replaces all partial system audits, providing a comprehensive vision of the situation of each audited centre compared to international standards (ISO 45001, ISO 14001, IATF 16949, ISO 9001) as well as against internal standards (Health and Safety systematics, Environmental Behaviour Index, TQM methodology and the SPG model).

BTM Key processes


16 key processes identified:

Health and Safety


The Health and Safety model at Gonvarri Industries is based on the principle of integrating Safety throughout the organisation, by dividing the responsibilities among all participants in the organizational structure, in all the decisions that are made, and in all the new processes and projects that are taken on.

This commitment was reinforced in 2011 when the CEO launched the ¨One Step ahead¨ plan, and in 2014 with the inclusion of a specific axis for Health and Safety in the global Strategic Plan of Gonvarri Industries and in 2017 the “Doing Well by Doing Safe” Safety Plan.

73% of our factories are certified under international health and safety standards (ISO 45001).

A total of 81 accidents with leave and 306 accidents without leave occurred during the year.

Environmental


ISO 14001 certification: 82% of factories.

Circular Economy

Steel is infinitely reused, melted and reshaped; iron and the other metals used to produce it have inherent chemical and physical properties that are not altered when they are recycled. It’s the most recycled material in the world.

In addition, life cycle analyses show that the use of recycled steel considerably reduces the consumption of natural resources and raw materials.

. Integrated scrap management

Scrap is the main waste generated at Gonvarri and is also 100% recyclable. The Company has an integrated system in all the plants of the group for the centralized collection and recovery of steel discarded in the production process.

In 2020 a total of 269,920 tons of scrap were processed (98.2% steel and 1.8% aluminium).

. Purchases of recycled steel

A large part of the steel used in Gonvarri´s processes comes from recycled steel.

We estimate that 36% of the steel used in the group has recycled origins which, in addition to our efficient scrap management, favours the development of a more circular steel value chain.

. Abstract Project V SAQA V4

At Gonvarri, among the waste with the greatest environmental impact are spent acids, which are generated in the carbon Steel pickling and dip galvanizing processes, each of which involves different characteristics.

For the recovery and valorization of these compounds an innovative project is being developed under an agreement between Gonvarri Industries and the National Center for Metallurgical Research (CENIM.CSIC), in collaboration with the Physics Department at the Complutense University of Madrid and the Rocasolano Institute of Physical Chemistry (IQFR).

. The carbon footprint project: Solar Structures

The manufacturing process for solar structures is grouped into different stages: the first is raw materials, the second is transportation, the third is Gonvarri’s Solar Steel production process, the fourth is transportation to clients and the fifth is waste treatment.

Our main conclusions are:
– Raw materials are the main source of CO2 emissions, followed by the galvanizing process.
– Considering processes at Gonvarri Solar Steel, on the one hand are the general production processes (cutting, welding and profiling) which only account for 1.5 – 1.6% of the total and, on the other, the galvanizing and paint processes which are estimated to have 12 times the impact of general processes.
– The carbon footprint of transporting raw materials is much lower than customer transport since most of the steel is purchased locally or in Europe and travels mainly by sea and rail. However, customer transport frequently reaches more remote locations and relies heavily on road travel.

SPG Gonvarri Production Systems


Based on the Toyota Production System (TPS), the Gonvarri Production System (SPG) is the Lean Manufacturing program of Gonvarri.

The working method is that each Gonvarri´s interiorize the most efficient way to carry out their work, improving day by day, within a framework of full communication with their co-workers.

Quality and customers


Gonvarri´s success is based on our capacity to identify and meet our customers´ needs. The keystone is the certification of all our companies in the quality management systems IATF 16949 (Auto and Industry) or ISO 9001 (Metallic Structures).

The various certification/recertification or follow-up audits carried out during 2020 have been affected by the various confinements and travel restrictions, requiring extraordinary measures to maintain the certificates: extensions of certifications, specific audits of the documentary and remote part, etc. Thanks to this and to the involvement of the teams, there have been no significant incidents.

Gonvarri Library

Gonvarri Library was set up in 2020, as a DRIVE Document Channel, the only repository of all official Corporate documentation, where one can find all the rules, standards, controls, procedures, guides, etc., defined by Main Headquarters and applicable to the entire organization so the Group may operate properly.

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