Savings through material audit Material audit improves production duction Director Pekka Oikarinen from Lumon. reducing aluminium profile sawing waste, says Pro- by and wastage, of analysis detailed more through sheets, jumbo glass of optimisation the improving ages for three of the company’s main products. theproduction glassof and aluminium profile pack balances focused particularly on the material flows materialin labour. The commodities,and energy and audit covered costs related to raw The materials, production. utilities in efficiency material improve to model,the purpose ofwhich isto identify measures materiala audit carried out using the Motiva’s audit of subjectthe wasLumon’sKouvola2010,plant In savings potential ofalmost EUR800,000. appraisal. The auditproduced atotal of68proposals for action,withanannual terraces, thecommissioned material auditturnedoutto beaproductive overall At LumonOy, acompany manufacturing balcony facade products andglazed efficiency. The audits bring out the tacit knowledge. companies look for targets for improving when operational capital valuable extremely be to prove may workshops.Thetacitknowledge productionof staff 800,000 motivated the participants of the audit and EURcalculatedalmost savingspotentialtheof and materials wasted of cost The line. production ing grind glass the of coolingimproving the for those included ideas new The them. among gems some fromcompany’sthe ownpersonnel, thereandwere before theappraisal. time good in brewing start to ideas allowed This successful. be to found was audit material the of findings the on information preliminary with bined com method workshop brainstorming The staff. the of enthusiasm Lumon’sthe bykey and persons shown commitment the were results the to utors contribwas conducted- Important byOyj. Etteplan model Motiva’s on based audit material Lumon’s Staff actively involved – The majority of ideas for material savings camesavings materialfor ideas ofmajority The The most significant savings are achieved by achieved are savings significant most The - - -

• • • Top 3actions • • Material audit’s findings • • • • The mainraw materials are aluminium and w materials meters for theuseandmonitoring of changing ways ofaction EUR 800,000 an annualsavings potential ofalmost 68 proposals for action The company employs over 600people. China. , , Russia, Canadaand and subsidiariesinGermany, , , company hasasecond factory inTampere designed mainlyattheKouvola works. The The products are manufactured and toughened orlaminated glass. balcony façade products andglazed terraces. Lumon Oymanufactures, sellsandinstalls aste monitoring system Product opment de v • • • • • • Motiva’s material audit el-

for thecompany’s development activities process andprovides valuable information Launches acontinuous development EUR 300,000 a savings potential of Audits carriedoutsofar have discovered of material flows Visual (Sankey) andgraphic presentation to materials usage andwastage Brings outdirect andindirect costs related aspects volume, cost, quality, andenvironmental Material flows analysed in terms of measures for improvement Systematic meansofseekingconcrete

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s Industrial symbiosis onmental information for supply chain – Material flow information 1million/year Implementing impr Identifying measur measur ov ement es es Envir commu- nication mental on-

Oikarinen comments. Pekka purchased, materials raw the from produce hensive review: how many finished products we can compre- a was approach the Now way. different a processin the of stages various the in wastage the fective measures for improving materials efficiency. ef most the resourcesto the allocate to helps and initiation of development projects emerging from it the environment. and resources natural saves and benefits, financial brings activity, the to structure adds that tool a is stretchtosystematic development work. The audit not do resources own their often but issue, the of ficiency of material usage and to take a positive view Companies are aware of the need to improve the ef Comprehensive review isbeneficial rinen says. Oikayear,- a in 400,000 EUR saved already have we result a as and costs, and materials in savings calculations. The results were also used as a basis for investment ing a more accurate system for monitoring wastage. The audit results were utilised at Lumon by creat – – An analysis of the current situation facilitates the Some of the proposals brought us considerable We have customarily measured and analysed and measuredWe customarily have www.motiva.fi/en tel. +358(0)424 2811 - - -

Ministry of Emploment and the Economy has financed the publication. Text: Motiva Oy – English text: Hele Andersson / Audipek – Photos: Lumon Oy Printed matter – Layout: Merja Sainio / Designio – Printing: Star-Offset, Helsinki – 11/2013 Number of copies: 500 – Paper: Munken Polar 200 g 441-338