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Episode 02 – Inventory: Simplified audit

Posted on: 9 June 2023

Welcome to TETRIS, the way to Factory 4.0!

In this first season, you’ll discover our 5-step roadmap for improving your plant’s environmental performance.
Here are the 5 steps:

Step 1 – Taking stock to prepare the ground.

Step 2 – Detailed analysis, where we explore your plant in depth.

Step 3 – Adjustments to optimize your plant’s performance.

Step 4 – Guidelines and master plan, to define and structure your ideal factory.

Step 5 – Continuous improvement to sustain your environmental performance.

Can you tell us, Sébastien, what a simplified audit entails in just one sentence?

It means assessing the maturity of each plant’s environmental performance. So why simplify? Because it’s not a detailed audit, and we’re going to collect the first data, whether on consumption, energy or production. Every plant knows its monthly energy consumption, since this is what we call the invoice. So the plant will have at least monthly data. We’ll also retrieve production data, which can be either tons of finished products, or even tons of finished products by product type.

Once we’ve collected this data, what else can we do?

Next, the simplified audit involves discussions with the company’s various stakeholders: management, management control, which will take an interest in energy through budgeting and monitoring invoicing. This will also involve technical discussions with maintenance, technical services and environmental managers.

It seems to me that there are also interviews to be carried out with people in the field, in the factory, the production teams, isn’t that right?

Interviews with production to find out their energy or water requirements for production and to see how they see these issues. These are the production workshops that consume all the energy and utilities. All these utilities are consumed by the process.

The aim is to assess the maturity of the environmental performance of our plants, and to find out whether we’re at the stage where we’re paying our bills, or whether we’ve already put things in place (are we already ISO 50001?). These are very different stages.

Do some plants already have an energy manager to deal with all these issues?

Indeed, the presence of an energy manager already shows a certain maturity of an industrial plant. I’m still surprised, after 25 years in the energy efficiency business, to see factories still treating energy simply as a bill. So they pay their bills and have no commitment to energy and environmental performance.

What is the main benefit of improving the energy and environmental performance of an industrial plant?

Energy and environmental performance are seen primarily from a financial point of view. Energy efficiency, reduced energy and water consumption all add up to euros.

How long does a simplified audit take?

It takes one, two or three days, depending on the complexity of the plant. In one day, we’ve already done simplified audits. What can influence this is the size and complexity of the plant.

Is a simplified audit mandatory?

No, it’s not an obligation. It’s not a regulatory audit. For us, the simplified audit is more of an inventory phase, but “simplified”. The aim is to assess the company’s maturity on the subject of environmental performance in a short space of time.

Who can carry out the simplified audit, and what skills are required?

To carry out a simplified audit, you need an expert who can quickly understand the plant and ask the relevant questions to the various stakeholders. He’ll also have a mind for synthesizing all this data.

In a nutshell

Initial mapping is the division of a plant into blocks. This breakdown into blocks becomes your standard to impose when an external or internal player comes to analyze your plant.

Initial mapping gives you a synthetic, global view of all your plant’s processes and flows.

It allows you to:

1. Visualize all plant components, from raw materials to finished products, processes and utilities.
2. Finally, it lays the foundations for defining THE standard for your plant.

In short, initial mapping is the starting point for your industrial environmental transition.