PUTTING THE PIECES TOGETHER - Getrag

PUTTING THE PIECES 

TOGETHER 

GETRAG Sustainability Report 2012

Imprint 

Issued by 

GETRAG International GmbH 

Hermann-Hagenmeyer-Straße 

74199 Untergruppenbach 

Germany 

Responsible 

Ulrich Schneeweiss, Vice President Strategy & Corporate Affairs 

Project Manager 

Silvio Sommer, Corporate Communications 

Concept & text 

Storymaker GmbH 

Derendinger Straße 50 

72072 Tübingen 

Germany 

Layout & typesetting 

Frank Oberhardt, Corporate Publishing & Corporate Design 

Photos 

Volker Schrank, www.volkerschrank.de 

EMAS-certified content 

Volker Ludwig, Senior Manager Global EHS 

Jürgen Schöneck, EHS and Quality Management Systems Manager 

Julia Moor, EHS student on placement 

In case of queries, please contact silvio.sommer@getrag.com 

We have decided not to print this report in order to conserve natural resources. 

2 PUTTING THE PIECES TOGETHER

“We are beginning to see our 

business differently” 

Dear readers, 

Today, our company comprises 23 locations and more than 12.500 staff 

worldwide. With this size comes strong economic potential but also great 

responsibility, for our increasing number of employees, theour products and 

technology that we produce, the mobility needs of the next generation but 

also in our use and consumption of raw materials, energy and other natural 

resources. 

As the global population of the world continues to increase and these many 

people around the world enter an industrializsed consumer society the use 

of natural resources will increase exponentially at current conditions. While 

this represents an opportunity for GETRAG to grow and innovate globally there 

will be increasing need to manage the impact our business has upon the 

environment around us and our use of precious natural resources upon which 

we depend. 

Sustainable economic development will become central and critical to the 

development of the global economy. This sustainability report marks the 

beginning of a longer journey as we begin start to understand our business 

differently and adapt to a changing set of mobility needs, economic conditions, 

environmental imperatives and use of resources that will meet the needs of 

future generations. 

Yours sincerely, 

Mihir Kotecha 

CEO

TABLE OF CONTENTS 

6 10 16 20 

GETRAG DATA 

STRATEGY AND 

PEOPLE AND GETRAG 

ENVIRONMENTAL 

AND FACTS 

MANAGEMENT 

Systematic sustainability and 

risk management at GETRAG 

will provide the framework 

for sustainable growth. In this 

respect, we are taking economic, 

ecological and social issues into 

account. 

Our values are: Precision. 

Passion. Partnership. We can only 

maintain these values by being 

an attractive and fair employer 

for whom skilled and capable 

employees are happy to work for 

a long time. 

PROTECTION 

For us, environmental protection 

has two aspects: sustainable 

processes keep GETRAG’s 

ecological footprint small, while 

our products contribute towards 

the greater environmental 

compatibility of the car. 


24 30 32 34 

PRODUCT 

SUSTAINABILITY 

SOCIAL COMMITMENT 

APPENDIX 

STEWARDSHIP 

Our understanding of product 

stewardship ranges from 

production processes that save 

resources to the development 

of advanced transmission 

technologies that will meet the 

needs of future generations as 

well. 

IN THE SUPPLY CHAIN 

Through comprehensive selection 

processes and continuous 

reviewing, we ensure that our 

suppliers operate according to the 

values that we consider important 

for our company too. 

We want to give something 

back to society and humanity, 

beyond our economic role. 

Hence GETRAG promotes social 

projects and organises events for 

employees and their families. 

TABLE OF CONTENTS 

PUTTING THE PIECES TOGETHER 5

GETRAG DATA AND FACTS 

HEADQUARTERS 

Untergruppenbach 

NUMBER OF TRANSMISSIONS PRODUCED 

GETRAG 

GO 

GFT 

GAP 

2010 2011 

2.9 million 

3.4 million 

transmissions transmissions 

1.2 million 

(no axle 

axle transmissions transmissions) 

1 million 

6 PUTTING THE PIECES TOGETHER 

1.8 million 

0.6 million 

TURNOVER 

2010 2011 

GETRAG 2.6 billion euros 3 billion euros 

GO: 

1.4 billion euros 

GFT: 


GAP: 


NUMBER OF EMPLOYEES 

2010 2011 

GETRAG 13,450 12,516 

GO: 4,013 

GFT: 4,760 

GAP: 3,743 

* The fall in the number of employees is a result of selling the 

axle business and introducing a new method for counting the 

number of employees. For more information about the new 

counting method, see page 36 of the appendix.

HybridDrive 

PowerShift 

ExtendedDrive 

PRODUCT RANGE 

eDrive 

ManualShift 

Components 

GETRAG COVERS THE ENTIRE PROCESS CHAIN FOR TRANSMISSION PRODUCTION 

Idea and concept → Design → Prototyping → Test phase and vehicle integration → Mass production 

GETRAG DATA AND FACTS 


Corporate structure 

GETRAG 

| GETRAG Getriebe- und Zahnradfabrik Hermann Hagenmeyer GmbH & Cie KG | 

| GETRAG International GmbH | 

| GETRAG s.r.o. | 

| GETRAG S.p.A. | 

| GETRAG Americas GmbH | 

| GETRAG Transmissions Corporation | 

| GETRAG Transmission Manufacturing de México S. A. de C. V. | 

GETRAG FORD Transmissions 

GETRAG Asia Pacific 

| GETRAG FORD Transmissions GmbH | 

| GETRAG FORD Transmissions Sweden A.B. | 

| GETRAG FORD Transmissions Slovakia s.r.o. | 

|GETRAG Asia Pacific Transmission Technology (Shanghai) Co. Ltd. | 

| GETRAG (Jiangxi) Transmission Co. Ltd. | 

More on the legal form and organisational structure in the appendix (page 36). 


Locations 

GERMANY 


NORTH AMERICA 

Irapuato 

Sterling Heights 

EUROPE 

Bari 

Bordeaux 

Halewood 

Kechnec 

Gothenburg 

Schaffhausen 

Cologne 

(Merkenich/Niehl) 

Neuenstein 

Rosenberg 

Bad Windsheim 

St. Georgen 

Neuenstadt 

Ludwigsburg 

ASIA 

Nanchang 

Yudu 

Shanghai 

Ganzhou 

Sanand

“Only quality products are 

sustainable” 

Olaf Kunde 

Vice President QEHS 

Quality is a feeling that must be continuously measured. 

Only when we work optimally with high-quality materials 

can we guarantee the properties, durability and 

efficiency of our products. So for us, quality is the most 

important prerequisite for our success in the market 

and thus for our continued growth as well. At GETRAG, 

we have optimised our structures and processes and are 

well prepared for all technological trends. For only those 

who plan ahead can be really sustainable.

STRATEGY AND 

MANAGEMENT 

A family business has to operate on a sustainable basis in order to survive in the long term and remain 

independent. Hence sustainability at GETRAG has three aspects of equal importance: economic, social and 

environmental. Only with happy and motivated employees can we apply the innovative power required for 

long-term, socially acceptable growth centred around motor vehicles. Systematic sustainability and risk 

management provide the framework for this. 

Environmental protection has been embedded in 

our corporate vision as one of the core objectives 

since 1989. That was three years after the 

Chernobyl nuclear disaster which made the world 

aware of the risks of technological progress in the 

most drastic way. The terror attacks of 9/11 and 

the financial crisis of 2008 also had a major impact 

on today’s sustainability and risk management at 

GETRAG: although, in the past, the focus was on 

environmental protection and occupational health 

and safety, we now take a more holistic view and 

are working on the introduction of a sustainability 

management system. 

Advanced EHS organisation 

The basis for our integrated environment,health 

and safety management system is a global 

Environment, Health and Safety Handbook, which, 

in addition to worldwide (level 1), also contains 

nationwide (level 2) and site-specific (level 3) 

procedural guidelines. 

DIN ISO 26000, the “Guidance on Social 

Responsibility” standard, was published in 2010. 

This directive is broken down into the core issues 

below, which were all taken into account when 

developing our sustainability management system: 

■■ 

■■ 

■■ 

■■ 

■■ 

■■ 

■■ 

Organisational governance 

Human rights 

Labour practices 

Environment 

Fair operating practices 

Consumer issues 

Community involvement and development 

Extract from our corporate 

vision “We do it better” 

Environment 

…which is why we act in the awareness of our 

social responsibility and actively support a 

balanced relationship between ecology and 

economy in order to preserve a world worth living 

in for future generations. 

Associates 

…which is why we positively and respectfully 

support and interact with each other in order to 

act independently and responsibly. We solve the 

assigned tasks in a trusting and creative working 

environment so that work is fun. 

STRATEGY AND MANAGEMENT 


Environmental protection and occupational 

health and safety is everyone’s concern 

The guiding principles of GETRAG’s corporate vision are embodied in our Environment, 

Health and Safety (EHS) Policy. We see this as a natural obligation of our enterprise, 

for which the employees are also required to bear personal responsibility. Starting 

with the German parent company, this EHS policy was transferred internationally 

to all GETRAG Operations enterprises and thus integrated into all business areas. 

Across the globe, all our sites have an environment, health and safety management 

system in accordance with the standards ISO 14001 and BS OHSAS 18001. The GETRAG 

Operations sites in Italy and Germany are even validated according to EMAS as well. 

We are committed: 

■■ 

■■ 

■■ 

■■ 

■■ 

■■ 

■■ 

■■ 

to be socially responsible, not to endanger the environment or the health and 

safety of people, and to preventive health care 

to continuously improve environmental protection, occupational health and safety 

to comply with applicable laws and other requirements 

to involve, inform and train our associates and relevant service providers 

to promote sustainability 

to the responsible use of natural resources and to reduce environmentally harmful 

emissions and waste 

to implement and maintain a certified environment, health and safety (EHS) 

management system at all locations 

to involve and inform interested parties; e.g. customers, suppliers, service 

providers, other partners, our neighbours, and regulatory agencies, striving 

towards better environmental protection, and occupational health and safety 

Various risks to consider 

The world keeps on turning: new transmission concepts arise, markets and customer 

needs change, sometimes rapidly, and in addition to this, there are the shifts in social 

and legal frameworks. We have to be prepared for such changes. Hence, consistent 

risk management is an important prerequisite for running a successful business in the 

21st century. 

Every business activity entails risks. So we try to find the right balance – between 

minimising risks and seizing opportunities. GETRAG has a company-wide, mandatory 

risk management system and all employees are involved in its active implementation. 

Operational responsibility lies with the division, project and programme managers. 

The entire process is controlled by our Risk Management Office (RMO), which reports 

directly to the Chief Financial Officer (CFO). This structure aims to establish a 

functioning risk management system that helps us identify the warning signs in good 

time and respond accordingly. 

Risk management at GETRAG is divided into four stages: 

■■ 

■■ 

■■ 

■■ 

Risk identification 

Risk analysis and assessment 

Implementation of appropriate measures 

Continuous monitoring and communication of risks 


1987 The Brundtland Commission of the United Nations defines a concept of sustainable development under the title “Our common future” 

1989 Environmental protection is embedded in GETRAG’s corporate vision 

1996 Rosenberg is the first site with validation according to EMAS 

2002 Occupational health and safety requirements are systematically implemented at GETRAG 

2003 Integration of environment, health and safety management 

2004 

2006 

2008 

All sites are certified according to ISO 14001 and BS OHSAS 18001. In addition, 

all European GETRAG Operations sites are validated according to EMAS 

Intensification of training and personal responsibility for implementing objectives and programms within 

the organisational units to promote greater environmental awareness in the employees 

Given the Environmental Award of the state of Baden-Württemberg for outstanding achievements in the 

promotion of corporate environmental protection and environment-oriented business management in the Industry category 

2010 

Publication of the basic principles of social responsibility 

2011 

Comparative survey of the status quo of social responsibility at all sites, deriving measures for improvement 

2012 

Implementation of a sustainability management system 

STRATEGY AND MANAGEMENT PUTTING THE PIECES TOGETHER 13

Our basic principles of social responsibility 

Corporate objectives at GETRAG must take social aspects into account 

– otherwise business activities would not be consistent with the 

interests of society. GETRAG is committed to basic principles of social 

responsibility that are not only the basis of our corporate activities, but 

also determine the cooperation with our business partners. These basic 

principles are based on internationally recognised guidelines: 

■■ 

■■ 

■■ 

■■ 

Universal Declaration of Human Rights of the UN 

Core Labour Standards of the ILO 

ILO Declaration of Fundamental Principles and Rights at Work 

OECD Guidelines for Multinational Enterprises 

International, national and local regulations, labour legislation and other 

contractual or non-contractual agreements, if any, also apply. 


Human rights 

We respect the dignity of every human being and support compliance 

with internationally recognised human rights. We reject all forms of 

physical, sexual, psychological or verbal abuse of our employees. We 

respect the right to freedom of opinion and expression. 

Rights of children 

We do not tolerate child labour and we respect the rights of children. 

We comply with the applicable rules regarding the minimum age for 

admission to employment or work. ILO Convention No. 138 and No. 182 

are observed in all GETRAG companies. 

Fair working conditions 

Our remuneration and social benefits are at least equal to the respective 

national or local standards or regulations. We observe ILO Convention 

No. 100 on the principle of equal pay. We comply with the applicable 

rules on working hours and holidays. 

Free choice of employment 

We reject all forms of forced labour and respect the principle of free 

choice of employment. We observe ILO Convention Nos. 29 and 105. 

Equal opportunities 

We safeguard equal opportunities for our employees, regardless of skin 

colour, gender, age, nationality, social, geographical and ethnic origin, 

religion, disability and sexual orientation. We comply with the rules of ILO 

Convention No. 111. 

Employee representatives 

We recognise the right of association of all employees. We work constructively 

with the respective representatives to protect the interests of our employees. 

We respect the right, within the framework of the respective legal regulations, 

to collective bargaining as a means of regulating working conditions. 

Occupational health and safety 

Our employees work in a safe and healthy working environment that meets 

or exceeds the national and international standards for health and safety in 

the workplace. We check this regularly and introduce suitable measures if 

necessary. 

Corruption 

We tolerate neither the acceptance of inappropriate gifts or favours from 

persons or organisations nor the corruption of other persons, organisations 

or political institutions by means of such gifts or favours in order to obtain 

financial or personal gain. 

The environment and sustainability 

Commitment to preserving and protecting the environment is important to us. 

Our ecological responsibility is the foundation of numerous initiatives in our 

corporate divisions. 

Implementation and responsibilities 

We publish these principles throughout the entire organisation. We ask our 

business partners to introduce and apply comparable principles of social 

responsibility in their companies. Employees who report a violation of these 

principles or assist with an investigation relating to such a violation shall not 

suffer prejudice of any kind. 

STRATEGY AND MANAGEMENT PUTTING THE PIECES TOGETHER 15

“Our culture connects us 

globally” 

Iris Schneider 

VP HR Business Partner PD & Central Staff 

Today, GETRAG is a global company with 23 different 

locations. Yet a common identity is not always a matter of 

course: local conditions and cultures may be too different. 

Hence learning from one another and mutual support are 

important issues at GETRAG. We create the motivation 

for this by providing a wide range of personal career and 

development opportunities. At GETRAG, responsibility is not 

just a matter for the boss; it is required of each and every 

employee. For me, this is part of our identity and helps us 

grow together in a sustainable manner.

PEOPLE 

AND GETRAG 

Precision. Passion. Partnership. These are our values and they apply to each and every employee. On this 

basis, we aim to ensure economic stability and sustainable profitability for our company. GETRAG can only 

achieve this by being an attractive and fair employer for whom skilled and efficient employees are happy to 

work and are able to develop. We therefore assume responsibility for all members of the global GETRAG 

family. 

A wide variety of cultures and 

nationalities 

All GETRAG sites are “international” in that people 

from various countries and cultures work at each 

one. We see this as an important competitive 

advantage because the composition of our teams 

reinforces our global orientation. 

Since 2010, the company has adopted a matrix 

organisation structure. This allows us to exploit 

the advantages of our cultural diversity more than 

a rigid hierarchy would. It is important to us that 

people with different cultural experiences work 

together at all decision levels. 

Personal development as a 

strategic issue 

In order to anticipate trends in the automotive 

market, our employees must always be one step 

ahead. To this end, we must provide them with 

the opportunity to continuously develop. Personal 

development is therefore a strategic issue for the 

management at GETRAG: 

They regularly discuss potential options with 

each individual employee – with a view to the 

key skills that will be required in the future, of 

course. Our personnel development officers and 

our management tools keep this process moving 

continuously. 

In this respect, besides having the technical skills 

(technical competence), at all levels we also 

value the ability (methods competence) and the 

willingness to act with mutual responsibility (social 

competence). The GETRAG Academy, with its wide 

range of courses, is an important component in 

implementing this process. 

For us, sustainable personnel development means 

a long-term commitment to our employees. 

Thus the staff turnover rate at our German sites 

increased only marginally in 2011 – from 5.9 to 6.2 

percent. In Italy, the 2011 turnover rate was just 

under 6.4 percent. Mexican workers, on the other 

hand, are generally more willing to change jobs 

than, for example, European workers, perhaps 

because of the high economic growth at the time. 

The turnover rate at the GETRAG site in Irapuato in 

2011 was therefore some 20.8 percent. 

PEOPLE AND GETRAG PUTTING THE PIECES TOGETHER 17

Systematic training has a long 

tradition 

The future is being created in the minds of the 

employees. Our company founder, Hermann 

Hagenmeyer, was guided by this motto when 

the first training workshop for transmission 

mechanics was established at the Ludwigsburg 

site in 1950. In-company training has been an 

important part of GETRAG’s corporate strategy 

ever since. Today, we not only train industrial 

mechanics, but also our commercial and 

technical staff. In addition to vocational colleges, 

the Cooperative University of Stuttgart (Duale 

Hochschule Stuttgart) and the Heilbronn University 

(Hochschule Heilbronn) are also partners in our 

dual training concept, which comprises both 

practical and theory modules. At GETRAG, there 

are currently 120 apprentices aiming to become 

industrial mechanics, mechatronics technicians 

and electronics engineers. In addition, there are 50 

students in the fields of mechanical engineering, 

electrical engineering, industrial engineering, 

mechatronics, business studies and automotive 

system engineering. Every year, dual students 

from Germany complete several weeks of practical 

training at an overseas GETRAG site. Our goal is to 

offer all apprentices and students a job once they 

have completed their training. As they are already 

familiar with the company and its philosophy, they 

are very well placed to quickly become respected 

members of the global GETRAG family and help 

drive the company forward. 

Target for occupational safety: 

0 accidents 

At GETRAG, we systematically record and analyse 

all accidents and potential risks. The corrective 

and preventative measures we derive from doing 

so are implemented as quickly as possible so as 

to avoid repeat accidents. Our analysis has shown 

that lack of attention is the most common cause of 

accidents. We therefore promote safety awareness 

among all employees and are actively working on 

the following issues: 

• Development of a safety management culture 

(in critical situations or in case of failure 

to obey rules, a manager must intervene 

immediately, demand compliance with 

the regulations, carry out regular safety 

inspections and give briefings, etc.) 

• Zero tolerance for critical situations and 

unsafe actions 

• Consequences for clear and repeated 

misconduct 

The comparative statistics for 2009 to 2011 show 

continuous improvements in occupational safety 

for the German sites: 

• 2009: 60 accidents led to 646 lost days 



Across all sites, we are working towards the longterm 

objective of “zero accidents at work”. 

Accidents 

Lost days 

Rosenberg 7 46 

Ludwigsburg 3 18 

Neuenstein 12 101 

Bad Windsheim 6 57 

Neuenstadt 0 0 

Untergruppenbach 3 36 

St. Georgen 0 0 

GETRAG Germany 31 258 

Bari 43 654 

Irapuato 4 40 

Accidents in 2011 


Health management as an 

investment 

In accordance with our principles of social 

responsibility, the health of all employees is a 

top priority at GETRAG. Hence in October 2011, 

we launched a company-wide project regarding 

workplace health management. As part of this 

project, in addition to the demographic trends in 

our employee base, we are also analysing: 

• The sickness rates and any characteristic 

diagnoses of individual age groups and staff 

groups, taking into account health insurance 

reports 

• Situational prevention, i.e. measures for 

maintaining health such as workstation 

ergonomics, lighting, lifting aids, working time 

arrangements or the organisation of work 

for example. This is based on a number of 

statutory provisions. 

• Behavioural prevention, i.e. the health 

awareness and initiatives of our employees. 

The employer could offer assistance in 

the form of advice regarding relaxation 

techniques, back and spine exercises, 

cardiovascular training or time and stress 

management for example. 

Career with family 

When you enter the foyer of the GETRAG 

InnovationsCenter at our headquarters in 

Untergruppenbach, you immediately notice the 

laughter of children and the Bobby Cars: this is 

because the site’s company nursery is right behind 

the reception. This nursery made us one of the 

first companies in the region where employees 

and visitors alike could see the work/life balance 

working in practice. 

We introduced flexible working hours and 

working from home for the Administration and 

Development divisions back in 2000 – in an effort 

to achieve a better work/life balance. There are 

even a set number of hours working time and 

mandatory attendance times only where they are 

absolutely necessary. 

Demographic change 

We have been keeping a very close eye on the 

demographic trends for our sites over recent 

years. This is the only way to ensure we can 

respond with a suitably honed personnel policy. A 

project team develops concepts and solutions for 

the associated challenges, for example specific 

measures for promoting health amongst older 

employees or optimised workstation design. For a 

number of years, GETRAG has also been making 

increased efforts to interest women in technical 

careers at the company. The age structure at 

GETRAG underwent positive changes in 2011: the 

number of employees between the ages of 20 and 

29 rose disproportionately. This is proof that the 

company has recovered well from the crisis of 

2009 and is on a growth course. There is a demand 

for young professionals in all divisions. 

Disability is no obstacle 

At GETRAG, representatives for the severely 

disabled promote the integration of the disabled 

and severely disabled. They also represent the 

interests of the disabled and are there to advise 

them. The representatives must be informed of 

and consulted about any and all matters relating 

to an individual disabled person or severely 

disabled people as a group. The representatives 

for the severely disabled and the employer work 

together on the basis of an integration agreement. 

PEOPLE AND GETRAG PUTTING THE PIECES TOGETHER 19

“We are part of a bigger 

whole” 

Manfred Zott 

Senior Maintenance Manager 

Natural cycles impress me time and again because, in 

nature, there is no division between economy and ecology. 

Nature also knows no waste. At GETRAG, we are working 

hard with resources that can regenerate or be recycled 

within production and also when our products reach the 

end of their life cycle. This gives us the chance to close 

material cycles. That, for me, is an important contribution 

to environmental protection and must always be at the 

heart of a comprehensive sustainability strategy.

ENVIRONMENTAL 

PROTECTION 

For GETRAG, environmental protection is a strategic issue in two respects: on the one hand, our processes 

must be as sustainable as possible in order to keep our ecological footprint small and on the other hand, our 

products must help make cars more environment-friendly and help facilitate individual mobility for future 

generations too. Both aspects help secure the future viability of GETRAG. 

Environmental management 

Just as nature works in cycles, GETRAG is also 

part of many processes and cycles. All internal 

processes are controlled by mandatory guidelines 

for EHS: from contract structuring to project 

planning and development, materials procurement 

and the logistics concept through to production. 

Economy, energy and resource efficiency as well 

as environmental compatibility are important 

criteria for all these processes. 

Even production support functions such as facility 

management, maintenance, quality management, 

personnel management or the IT department are 

subject to EHS requirements and are regularly 

reviewed with respect to their environmental 

impacts and optimised accordingly. 

Optimisation of GETRAG processes at the 

production sites to: 

■■ 

■■ 

■■ 

■■ 

Achieve high energy efficiency 

Implement technologies that save resources 

Avoid wastewater, waste and emissions 

Firmly establish uniform environmental 

standards throughout GETRAG 

Optimisation of GETRAG products to: 

■■ 

■■ 

■■ 

■■ 

Minimise fuel consumption by: 

»» 

Maximised efficiency 

»» 

Weight-optimised construction 

Ensure the designs and the materials chosen 

lend themselves well to recycling 

Use non-toxic components 

Produce low-noise gearing 

ENVIRONMENTAL PROTECTION PUTTING THE PIECES TOGETHER 21

Energy efficiency equals climate protection 

Fossil fuels such as crude oil and natural gas are getting more and more expensive 

and their combustion accounts for a significant share of the world’s CO 2 

emissions. 

We are increasingly using environment-friendly energy sources and are therefore 

actively contributing towards achieving international climate protection objectives. One 

example of this is our cooperation with a biogas generator at the Rosenberg site. 

undergo an approval process involving the EHS representatives and the occupational 

physicians for the site. Better yet would be to avoid using any harmful substances 

at all: we run workshops to see whether there is any chance of substituting these 

materials at least every six years. 

Production process: growth and greater efficiency 

GETRAG grew in 2011. Naturally, this also led to an increased consumption of raw 

materials, energy and water as well as increased volumes of waste and emissions. 

Production volumes have risen substantially, especially at our plants in Irapuato, 

Mexico, and Bari, Italy. If you compare the environmental performance figures based 

on consumption and emissions per ton of material used, you will get a distinctly 

positive picture of GETRAG’s resource efficiency: energy and water use has fallen, our 

production process has therefore become more efficient compared with 2010. 

Reducing operating and auxiliary materials 

For manufacturing and heat treatment of transmissions, GETRAG also requires waterhazardous 

substances such as transmission oils, hydraulic oils, cutting fluids, cleaning 

agents or methanol. To avoid any risk of soil or groundwater contamination, the floors 

of the relevant production areas are sealed with a media-impermeable coating. Tanks 

are generally double-walled and equipped with leak detection technology. We no longer 

install new tanks and pipework systems underground because it is easier to detect 

leaks with systems above the ground. GETRAG is continuously optimising its production 

processes – with the aim of, amongst other things, further reducing the consumption 

and stock levels of operating and auxiliary materials. All operating and auxiliary 

materials that are potentially harmful to the environment or to health 

Water consumption [l/t] 

5.000 

4.500 

4.000 

3.500 

3.000 

2.500 

2.000 

1.500 

1.000 

500 

0 

2010 2011 

Waste [kg/t] 

350 

300 

250 

200 

150 

100 

50 

0 

2010 2011 

Water is precious 

Washing and cleaning processes cannot be 

performed without water and this is the case at 

GETRAG too. Also, water-mixed coolants and 

chilled water are required for the production 

process. Even the building services equipment, 

sanitary facilities, canteens and gardens consume 

considerable amounts of water. To reduce 

water consumption in the long term, GETRAG is 

increasingly using dry machining and minimalvolume 

lubrication technologies; washing 

processes are also being optimised. 

Waste is recyclable 

Waste today is too valuable not to be reused or 

recycled, including at GETRAG. Hence, in recent 

years, we have extended the waste collection 

points at the sites to create recycling centres. The 

aim is systematic recycling or environmentally 

sound disposal. The site waste representatives 

regularly review GETRAG’s external waste disposal 

partners – looking for legal compliance and 

sustainability. 


Limiting emissions 

At GETRAG, the largest contributor to CO 2 

emissions is the external electricity supply 

based on fossil fuels (see “Energy efficiency equals climate protection”). Other 

emissions include oil mist and oily aerosols, which occur when cutting metal parts for 

transmissions. At GETRAG, these are removed by local filtration systems directly at the 

processing machine or by central exhaust air systems. We mainly use electrostatic and 

mechanical filters in this respect. 

Emissions also occur during heat treatment, which is necessary to harden the surface 

of the components produced. The composition of the resulting exhaust gases depends 

on the method used – where appropriate, the machines have exhaust gas treatment 

systems. In transmission development, the majority of emissions arise during testing 

when combustion engines are used as the drive source. Using the latest generation 

of catalytic converters and particulate filters, GETRAG meets the current EU emission 

regulations for motor vehicles. The rise in CO 2 

emissions can be attributed, for the 

most part, to the increased consumption of electrical power compared with 2010. 

Energy sources 

Electricity 

CO 2 

emissions 

Heating oil 

2010: 

3,344.06 kWh/t 

Natural gas 

District heating 

Diesel for transmission test rigs 

2010: 

1,098.54 kg/t 

2011: 

-10% 

Petrol for transmission test rigs 

Flights 

2011: 

-2.35% 

The diagrams are based on consolidated numbers. More diagrams, an input/output table 

with exact data as well as measures and objectives of the individual sites are given in the 

appendix from page 37. 

ENVIRONMENTAL PROTECTION 


“We are making our products 

more efficiently” 

Sebastian Nowak 

Production worker 

I enjoy driving. This is probably natural for someone who 

builds transmissions. I find it exciting that transmissions, 

and therefore the products in our range, are so incredibly 

varied nowadays. It all depends on the mobility requirements 

of people around the world. At GETRAG, we have the right 

products for all technologies. An end to development is still 

far from sight: the potential for innovation in automotive 

engineering is huge. My colleagues and I work hard every day 

to make our transmissions better and our processes more 

efficient. At the end of the day, my son also likes driving.

PRODUCT 

STEWARDSHIP 

Our products have been in use around the world for several decades. With the growing desire for individual 

mobility, especially in rapidly developing countries, demand for GETRAG transmissions will also grow in the 

coming decades. This means we have a responsibility to produce durable, low-maintenance products with 

maximum resource-efficiency. With our innovative might, we want to ensure that our transmissions will be 

part of all future drive technologies. 

Transmission recycling 

Recycling usually refers to packaging and 

packing materials. However, even transmissions 

can be fed into a similar cycle. Hence, GETRAG 

has implemented “return agreements” with 

several customers. Already in 2011, we recycled 

parts from nearly 1,500 car and motorcycle 

transmissions within the context of pilot projects. 

We carry out some of this recycling ourselves, 

but we also get support from selected suppliers. 

As part of a study at group level, we are currently 

evaluating the efficiency of the pilot projects. 

Based on the results of this study, we will be able 

to assess the future viability of this approach and 

make a decision about its further development at 

GETRAG. 

Environment-friendly 

processes 

The production of transmissions is our main 

business. The resources required for this are 

raw, auxiliary and operating materials as well as 

drinking water and energy. Wastewater, waste and 

emissions are produced during the manufacturing 

processes. 

The production process at GETRAG is divided into 

the following subprocesses: 

■■ 

■■ 

■■ 

■■ 

Planning 

Mechanical production (soft/hard machining) 

Heat treatment and 

Assembly (transmissions/components) with 

final inspection 

PRODUCT STEWARDSHIP PUTTING THE PIECES TOGETHER 25

Planning 

Mechanical production 

Planning 

The component-specific requirements for production and assembly as defined in 

product development are addressed during the planning process. During selection 

of the machinery and equipment, we already make a preliminary decision about the 

subsequent use of resources and the potential environmental and occupational health 

aspects such as dry machining, the use of operating materials and coolants, noise 

levels or energy consumption for example. Planning – that is the anticipatory 

coordination of the production environment, the cooling concept and the layout of our 

processes. For all technical investments and structural measures relevant to EHS, the 

company representatives for environment, health and safety as well as the 

occupational health service are involved right from the planning phase. 

Mechanical production 

The production process at GETRAG is characterised by a high degree of vertical 

integration and is dominated by metal-cutting steps. On the way to the ready-toassemble, 

high-precision finished part, the blanks undergo processing operations 

such as turning, drilling, cold rolling, milling, slotting, broaching, sharpening, grinding, 

honing and finishing. Between the individual production steps, the parts are washed, 

if required, in cleaning systems to remove stuck-on particles and cutting fluids. The 

production machines are supplied with cutting fluids through individual and central 

systems that are constantly monitored and cleaned. 


Heat treatment 

Assembly 

Heat treatment 

The transmission parts get their high strength and wear resistance through heat 

treatment in the hardening shop, mainly at the Ludwigsburg, Bari, Rosenberg, 

Neuenstein and Kechnec sites. This produces emissions such as oily fumes from the 

hardening and cleaning equipment, exhaust air from the phosphating equipment or 

metallic dust from the shot peening and blast cleaning equipment. To reduce these 

emissions, all sources of emissions have been fitted with extraction systems. 

To make heat treatment even more environmentally friendly and efficient, we use 

vacuum carburising systems with gas quenching. This eliminates the use of hardening 

oil as well as the cleaning of the workpieces and the subsequent shotblast cleaning. 

The vacuum carburising systems are integrated in the production process. 

Assembly 

Our final assembly and testing processes are carried out on the latest, partly robotic 

assembly lines. Out of the entire manufacturing process, assembly has only minor 

environmental impact. This impact results mainly from: 

■■ 

■■ 

■■ 

■■ 

The use of transmission oil for final testing and filling – the test oil used is recycled 

Filling the transmission with lubricating oil, in most cases with lifetime 

transmission oil that will last the entire life cycle 

The water needed for leak testing in the water bath and for cleaning prior to 

dispatch 

The packaging material used for the components supplied and for delivering the 

finished transmission 

For deliveries within the company and from external suppliers, we generally use 

reusable transport systems/packaging. Shipments to international customers are 

packaged in recyclable cardboard packaging, also known as seaworthy packaging. 

At GETRAG, all packaging material accumulated in the assembly area is collected, 

separated and recycled. 

PRODUCT STEWARDSHIP PUTTING THE PIECES TOGETHER 27

Transmission range 

GETRAG develops and produces transmissions for many well-known automotive manufacturers and offers a wide range 

of products: we develop manual transmissions, automated manual transmissions, dual clutch transmissions, motorcycle 

transmissions and transmissions for electric vehicles. Several designs are possible, including the classic installation for rearwheel 

drive (inline), the transaxle longitudinal installation with integrated axle differential (longitudinal) and the very popular 

front-transverse transmission (transverse). 

Manual transmissions 

Dual clutch transmissions 

ManualDrive 

Manual transmissions are the world’s most popular 

because they are cost-effective and offer a high degree 

of efficiency. To optimise efficiency, manufacturers are 

increasingly integrating an automatic start/stop function 

for the combustion engine. Further potential options for 

optimising fuel consumption lie in 

■■ 

■■ 

■■ 

■■ 

■■ 

The use of oils with low viscosity 

Active lubrication and thermal management 

Optimised sealing systems 

Improved wheelset design with optimised gear 

geometry and coated, reduced-friction gearing 

The use of lighter materials 

Like manual and automated transmissions, dual clutch 

transmissions (DCT) of the PowerShift product brand are 

based on the layshaft design. This technology enables 

completely seamless gearshifting: while one gear is 

engaged, the system has already preselected the next 

one. Once the engine reaches the necessary rpm, one 

clutch is closed while the second is opened, so the 

tractive force is not interrupted. The intelligent software 

control offers both sportiness and convenience combined 

with fuel economy and therefore lower CO 2 

emissions. 

In practice, fuel savings of about five percent have been 

measured. 

PowerShift 

Automated manual transmissions (AMT) combine the 

mechanical efficiency of the manual transmission with 

the operating convenience of automatic transmissions. 

Clutch operation and gearshifting are controlled 

electronically and supported by electric or hydraulic 

actuation. The driver can chose between fully automatic 

mode and gear selection in the style of a racing car driver. 

Gearshift timing is optimised with software support and in 

practice makes the largest contribution to reducing fuel 

consumption. 

Automated transmission types (AMT and DCT) are 

particularly suitable in combination with hybrid drives 

since the options for connecting an electric motor to 

the transmission are flexible. In conjunction with one or 

two electric motors, both transmission types allow an 

additional fuel saving of up to 25 percent. 

Extende 


Alternative drive systems 

eDrive 

GETRAG has been autonomously developing drive systems for all-electric cars since 

1992. In doing so, we have demonstrated the capability of such drives and accumulated 

know-how in terms of vehicle integration and electric drive technology. Aside from the 

battery, we have developed all the necessary components, including inverters, electric 

motor, transmission and controls, ourselves and manufactured our own prototypes. 

With electric drives, we focus on high-revving electric motors with correspondingly 

large gear ratios in order to exploit the weight and efficiency advantages compared with 

conventional medium-speed motors. Thus we obtain advantages in climbing ability and 

acceleration as well as an approximately eight percent greater range. 

HybridDrive 

Components 

dDrive 

GETRAG produces individual transmission components and also engine timing gear 

systems. Such systems are being used in more and more cars and lorries to drive 

camshafts and secondary engine units. Compared with chain or belt drive, timing 

gears are more durable and maintenance-free. If the actuator and accessory drive 

on the engine are positioned on the drive side, car manufacturers can save over 50 

millimetres of installation space, which among other things contributes towards 

improved pedestrian protection. Modern diesel engines require high injection pressures 

which are generated using a high-pressure fuel pump – the necessary drive torque of 

the pump is best generated via a robust spur gear arrangement. 

PRODUCT STEWARDSHIP 


“Suppliers and customers are 

our partners” 

Tanja Schmalzbauer 

Direct purchasing 

Many of our customers have been relying on us for decades 

because we at GETRAG have always set high standards. To 

keep it that way, in view of the global supply chains and 

markets, we also have to demand high standards from our 

suppliers and service providers. More and more consumers 

are paying attention to fair production conditions that 

save resources. Therefore we demand a sense of social 

responsibility from our suppliers. Ultimately, sustainable 

partnerships can only be forged and maintained if the 

partners share the same values.

SUSTAINABILITY 

IN THE SUPPLY CHAIN 

Responsibility for our products begins not in the design or production stage, but earlier on with our suppliers and service providers. We say: it is essential to ensure environmental 

and health compatibility throughout the entire supply chain. Only then we can handle our product stewardship in accordance with our corporate values. Through comprehensive 

selection processes and continuous reviewing, we also ensure that our partners share this responsibility. 

Systematic selection ensures reliability 

Global responsibility 

The materials, production equipment and even production support services are 

important factors when it comes to the design and efficiency of our processes and 

products. Therefore we choose our suppliers based not only on economic, but also on 

ecological and social criteria. Our purchasing department and the supplier teams thus 

decide directly on environmental and health-related material flows within the company. 

Providing environmental protection and 

occupational health and safety 

Potential suppliers to GETRAG must provide documentary evidence of their ability to 

meet the requirements placed on them and their products or services. This first step 

is self-disclosure via a supplier questionnaire. It is important for us that partners have 

implemented an environment, health and safety management system. If not, we require 

our partners to work towards introducing an EMAS or ISO 14001-certified environmental 

protection management system and a BS OHSAS 18001-certified occupational health 

and safety management system in the near future. If, during the contract award 

process, suppliers offer a similar quality, price and deadline, then we will favour the 

suppliers that work with an appropriate EHS management system. All GETRAG partners 

have been provided with the principles of social responsibility applied to our own sites 

as well as our environment, health and safety policy (see chapter 2) – together with the 

request to formulate and implement similar guidelines. 

Supply chains actually start before the direct supplier. They are based on global 

networks that are often difficult to see in their entirety. However, we need a clear 

picture of the origin, quality and production conditions of the materials and parts 

supplied. Our suppliers must therefore ensure that the environmental and occupational 

health and safety requirements placed on them are also met by their sub-suppliers. 

Only if the necessary documentation is transparent can companies be incorporated in 

GETRAG’s supplier pool. 

Continuity in the supplier relationship 

A systematic process for selecting suppliers starts off our sense of stewardship 

beyond the boundaries of our company. Thereafter, we need to ensure that suppliers 

continue to meet our requirements in the long term. To do this, GETRAG conducts 

on-site “supplier audits”. These audits, conducted at our partners’ premises, also help 

maintain long-term, strategic business relationships with suppliers. Furthermore, we 

support our suppliers in optimising unsatisfactory performance. 

SUSTAINABILITY IN THE SUPPLY CHAIN PUTTING THE PIECES TOGETHER 31

“A networked world must 

also be a fair one” 

Ivon Guadalupe Gutierrez Calderón 

Day-release student 

Economic development is only seen as progress 

if it opens up opportunities for as many people as 

possible. For me, this includes good training and at 

the same time it also provides the basis for giving 

something back to society. With this training, I 

will be able to make the right decisions later on 

in the workplace and let other people share in my 

success.

SOCIAL 

COMMITMENT 

As a company, GETRAG benefits from the diversity and inventiveness of the people in various countries. We 

are aware of this and like to give something back, so we involve ourselves in the local life surrounding our 

sites: we support communities, projects and, last but not least, the families of our employees. We want to 

actively help shape our social environment. 

Sponsorship and donations 

Sponsorship and donations are important 

aspects of GETRAG’s social commitment. We 

actively support projects and organisations in 

education, science, environmental protection, 

social welfare, sports and of course art and 

culture. This includes financial support, goods 

and services and volunteer work. GETRAG selects 

suitable projects and organisations according 

to its own criteria check list. For example, we 

check that funded projects are sustainable, will 

revitalise the community and are related to the 

respective site. Last year, we supported projects 

such as “Gemeinsam gegen Gewalt” (Together 

Against Violence) in Rosenberg, funds such as 

“Jugend, Bildung, Zukunft” (Youth, Education, 

Future) in Ludwigsburg and an initiative for drug 

prevention at the Ilsfeld secondary school near our 

headquarters in Untergruppenbach. Regardless 

of the predefined criteria for our commitment, 

however, GETRAG also helps in humanitarian 

emergencies such as the heavy floods on the river 

Elbe in Germany in 2002 for example. 

Irapuato donates 

Employees in Irapuato, Mexico, have been 

providing their community with financial support 

for some time now. Last year, for example, 

numerous donations were made to charities, 

including the children’s’ rehabilitation centre in 

Irapuato. This helped secure urgently needed 

prosthetics and orthopaedic insoles for 30 

children. They also supported the local migrants’ 

home with donations for blankets and clothes. In 

January 2012, GETRAG employees donated to the 

“La Purisima“ community. 

Family days at GETRAG sites 

in Germany 

We run family days for our current and former 

employees, their families and friends at all 

our sites, offering automotive technology they 

can experience close-up and entertainment 

for everyone. These events include product 

demonstrations and a lively presentation of the 

company’s history as well as a variety of family 

games. At GETRAG family days, local associations 

and institutions present themselves. That way, 

new/transferred employees and their families can 

learn about life at the site, its surroundings and 

leisure facilities. 

SOCIAL COMMITMENT PUTTING THE PIECES TOGETHER 33

APPENDIX 

REPORT PARAMETERS 

Table of Contents 

Report parameters...................................................................................Page 34 

Glossary....................................................................................................Page 35 

This sustainability report is the first of its kind for GETRAG. We used to publish comprehensive 

environmental statements every three years, which were of course updated in the intervening years. 

The last one was published in 2009. All previous environmental statements from GETRAG Operations, 

together with all environmental certificates, are available online at www.getrag.com. The next GETRAG 

sustainability report is scheduled for release in 2013 (for the reporting period 2012). 

Appendix chapter “GETRAG data and facts”...........................................Page 36 

Appendix chapter “Environmental protection“ 

- Diagrams...............................................................................................Page 37 

- Site descriptions...................................................................................Page 38 

- Site objectives.......................................................................................Page 40 

- Input/output balance............................................................................Page 43 

- Validation...............................................................................................Page 49 

GRI table...................................................................................................Page 50 

Reporting period and scope 

Unless explicitly stated otherwise, the information presented in this report relates to the fiscal year 

2011. 

The report contains an integrated environmental statement on the basis of which the German sites of 

GETRAG Operations are EMAS-certified in accordance with the validation in this appendix. Chapters 

2, 3, 4, 5, 6 and 7 as well as the appendices “Input/output table” and “Site descriptions, objectives 

and measures” therefore relate specifically to GETRAG Operations. The editorial, chapter 1 and the 

appendices “Organisational profile”, “Governance” and “Stakeholder groups” apply to the whole 

GETRAG corporation. 

Report content 

In compiling the content for this sustainability report, we followed the internationally recognised G3 

guidelines of the Global Reporting Initiative (GRI). In our judgement this report meets Application Level 

C. 

In order to select the relevant issues from the economic, environmental and social categories, we 

carried out internal workshops with managers from the respective divisions. 


GLOSSARY 

BS OHSAS 18001 

The Occupational Health and Safety Assessment Series is a worldwide certification basis for 

management systems relating to occupational health and safety. 

DIN ISO 

Term for a set of standards developed by the International Organization for Standardization (ISO) and 

adopted by the German Institute for Standardisation (Deutschen Institut für Normung, DIN) (e.g. 9001 

for quality management systems or 14001 for environmental management systems, etc.). 

eDrive 

eDRiVE refers to GETRAG solutions for all-electric mobility (only for the Asian market). 

EMAS 

The Eco-Management and Audit Scheme is a system developed by the European Union for 

environmental management and auditing. It is used by organisations that want to improve their 

environmental performance. 

ExtendedDrive 

We use ExtendedDrive to refer to the GETRAG Boosted Range Extender concept according to which an 

electric motor is supported by a combustion engine on longer journeys. 

GO 

As part of the process to simplify the corporate structure, GETRAG Group Transmissions (GGT) was 

merged into the parent company GETRAG at the turn of the year 2011/2012. GETRAG Operations now 

describes the sites and companies that formerly belonged to GGT. 

GRI 

The Global Reporting Initiative, as an independent institution, developed the guidelines preparing 

sustainability reports. Reports prepared according to the GRI are largely standardised and therefore 

comparable. 

HybridDrive 

This term encompasses GETRAG’s range of hybridised dual clutch transmissions (see also PowerShift). 

ILO 

The International Labour Organization in Geneva, Switzerland, is 

a subsidiary organisation of the UNO that develops recommendations and guidelines for promoting 

social justice as well as human and labour rights. 

ManualShift 

ManualShift refers to the GETRAG range of manual transmissions. 

GAP 

GETRAG Asia Pacific. The joint venture between GETRAG and GETRAG FORD Transmissions which was 

established in 2006 (see GFT) with plants in Nanchang, Ganzhou, Yudu and headquarters in Shanghai 

(China). The group specialises in the development and production of transmissions and transmission 

components for the Asian market. 

GFT 

GETRAG FORD Transmissions is a joint venture between GETRAG and Ford of Europe established in 

2001 with sites in Cologne (DE), Bordeaux (FR), Halewood (UK), Gothenburg (SE) and Kechnec (SK). 

GFT develops and produces transmissions as a full-service system supplier. 

OECD 

The Organization for Economic Co-operation and Development, with headquarters in Paris, France, 

promotes sustainable economic growth, higher levels of employment and better living standards. 

PowerShift 

This term encompasses GETRAG’s range of dual clutch transmissions (DCT). For hybridised dual clutch 

transmissions, see HybridDrive. 

(Q)EHS 

(Quality,) Environment, Health and Safety 

APPENDIX PUTTING THE PIECES TOGETHER 35

APPENDIX CHAPTER “GETRAG DATA AND FACTS” 

The following sections contain more specific information about the company. 

Countries, main operating companies and divisions 

GETRAG operates in 10 countries in total, its main operating companies being in Germany and China. 

There are also large plants in Great Britain, France, Italy and Mexico. 

The company is divided into the following main divisions: Manufacturing, Product Development, 

Marketing, Sales and Business Development, Purchasing, Finance/IT, Human Resources, QEHS and 

Strategy & Corporate Affairs. 

There is regular exchange with the shareholders. There are various ways for employees to submit their 

recommendations to the Management Board, including the Ideefix ideas management system and “Skip 

Level Meetings”, where the management skips managerial levels and engages in direct dialogue with 

the employees. 

Stakeholder groups 

GETRAG wants to offer society added value, beyond its capacity as an employer and product 

manufacturer. We are aware that creating sustainable added value takes more than just promoting 

social projects. 

Ownership structure and legal form 

The Hagenmeyer family owns 100% of the shares in GETRAG Getriebe- und Zahnradfabrik Hermann 

Hagenmeyer GmbH & Cie KG (GETRAG Operations). This is the parent company of the group, including 

all subsidiaries and two joint ventures: GETRAG FORD Transmissions and GETRAG Asia Pacific. The 

parent company is also operationally active. 

Markets and customers 

We supply our products primarily to the European, North American and Chinese markets. In Europe, 

our client base includes industry giants like Ford, BMW, Daimler, Renault and Volvo. In the USA, Ford 

is our largest customer, while in China, we sell our products to many national brands, including JMC, 

Qoros and Dongfeng. 

Hence, we are in constant dialogue with a wide variety of interest groups to help us understand their 

needs and desires and, as far as possible, we take these into account in our actions. To this end, we are 

in regular contact with suppliers, customers and, increasingly, the international press too. 

We are currently also working on a concept for increasing involvement of other groups, including NGOs, 

end customers and the global Internet public in its facets that are relevant for us. 

Method for counting the number of employees 

Up until 2010, the number of employees at GETRAG was reported as the average number across the 

year based on the FTE (full-time equivalent) value. 

Boards and exchange 

In addition to the corporate structure detailed in chapter 1, there is a five-member Advisory Board 

that has an advisory and monitoring role and reports to the management board. The Advisory Board is 

comprised of independent industry experts from various disciplines. 

Mihir Kotecha, as CEO, is Chairman of the Corporate Management Board, which is the highest 

governance body in the company and comprises ten people, three of whom are not members of the 

executive board. 


APPENDIX CHAPTER “ENVIRONMENTAL PROTECTION” 

In 2011, the method for counting the number of employees was changed. The number of employees is now being reported as the head count (the actual number of people) on the day of the count, 31 December. 

Furthermore, the significant difference is also due to the sale of the axle business and thus the departure of the employees that had been employed in this branch of the business. The following pages contain detailed 

information about our environmental balance. In the main part of this report, we present graphics depicting the measurement results in relation to the production volumes. This shows the efficiency in relation to the 

quantities actually produced. Here, you will find the absolute values without taking into account the increased levels of production: 

Energy source in kWh 

CO 2 emissions in t 

180000000 

180000000 

160000000 

180000000 

160000000 

140000000 

160000000 

140000000 

120000000 

140000000 

120000000 

100000000 

120000000 

100000000 

80000000 

100000000 

80000000 

60000000 

80000000 

60000000 

40000000 

60000000 

40000000 

20000000 

40000000 

200000000 

0 

20000000 

0 

0 

2010 2010 2011 2011 

2010 

2010 

2011 

2011 

Petrol Ottokraftstoff for transmission für für test rigs 

Getriebe-Prüfstände 

Ottokraftstoff für 




Dieselkraftstoff for transmission für für test rigs 


Dieselkraftstoff für 




District Fernwärme heating 

Fernwärme 

Fernwärme 

Erdgas Natural Erdgas gas 

Erdgas 

Erdgas 

Heizöl Heating Heizöl oil 

Heizöl 

Heizöl 

Strom Electricity Strom 

Strom 

Strom 

70000 70000 

70000 

60000 70000 60000 

60000 

50000 60000 50000 

50000 

40000 50000 40000 

40000 

30000 40000 30000 

30000 

20000 30000 20000 

20000 

10000 20000 10000 

10000 

100000 

0 

0 

0 

2010 2010 2011 2011 

2010 

2010 

2011 

2011 

Flüge Flights Flüge 

Flüge 

Petrol 

Flüge 

Ottokraftstoff for transmission für für test rigs 




Ottokraftstoff 

Dieselkraftstoff for transmission für 

für 

für test rigs 






District Fernwärme 


heating 

Fernwärme 

Erdgas 

Fernwärme 

Natural Erdgas gas 

Erdgas 

Heizöl 

Erdgas 

Heating Heizöloil 

Heizöl 

Strom 

Heizöl 

Electricity Strom 

Strom 

Strom 

Water in m 3 

250000 250000 

250000 

200000 250000 200000 

200000 

150000 200000 150000 

150000 

100000 150000 100000 

100000 

50000 100000 50000 

50000 

50000 0 0 

0 

0 

2010 2010 2011 2011 

2010 

2010 

2011 

2011 

Waste in t 

20000 20000 

20000 18000 18000 

18000 16000 

20000 

16000 

16000 14000 

18000 

14000 

14000 12000 

16000 

12000 

12000 10000 

14000 

10000 

10000 8000 

12000 

8000 

8000 6000 

10000 

6000 

6000 4000 

8000 

4000 

4000 2000 

6000 

2000 

4000 

20000 

0 

2000 

0 

0 

2010 2010 2011 2011 

2010 

2010 

2011 

2011 


SITE DESCRIPTIONS: 

GETRAG InnovationsCenter Untergruppenbach 

Established in 2002 

680 employees 

Group headquarters and headquarters of the executive board of GETRAG GmbH & Cie KG and 


Divisions: Development, Sales, Finance, Controlling, Purchasing, IT, Communication, Business 

Development, Corporate Identity, Personnel and QEHS 

Certifications: ISO 14001 since 2003, EMAS since 2003, OHSAS 18001 since 2004, ISO TS 16949 since 

2002 

In addition to the administrative divisions, the GETRAG InnovationsCenter in Untergruppenbach also 

houses a prototype production facility as well as laboratory and test rigs. Ecological criteria were 

considered even during planning of the building complex, resulting in favourable values in terms of 

energy and drinking water consumption. Today, the planted outdoor area with pond is home to many 

different animal species. 

GETRAG Plant Bad Windsheim 

Established in 1982 as Fränkische Zahnradwerke (FZ) 

388 employees 

Production of circuit components, housings, mechatronic parts and dual clutches 

Certifications: ISO 14001 since 1998; EMAS since 1998; OHSAS 18001 since 2004 

Aluminium transmission housings, flanges, circuit components and mechatronic parts for the GETRAG 

sites in Germany and Slovakia are produced in Bad Windsheim. The machining process required for 

this is performed both wet (with cutting fluid) and dry (using minimal lubrication technology). At the 

plant in Bad Windsheim, a compressed air master plan has been implemented since 2012 for longterm 

optimisation of the compressed air supply. The resultant heat energy is used to supply heat to the 

plant. The energy consumption of the clean room is to be even further reduced on the basis of a work 

placement agreed with the Triesdorf University of Applied Sciences. 

GETRAG Systemtechnik St. Georgen 


45 employees 

Development and calibration of transmission control software 


2002 

The software for GETRAG PowerShift transmissions is developed in St. Georgen. The current project 

includes optimising the start-stop function for the new application for the dry 6DCT250 transmission. 

As part of this process, customer needs and legal requirements have to be matched to each specific 

vehicle. Testing of the software is largely automatic. It is also environment-friendly since it is based on 

virtual simulations of the vehicle and the transmission components. 

GETRAG Plant Ludwigsburg 


148 employees 

Production of components, especially engine timing gears and sprockets 

Certifications: ISO 14001 since 2000, EMAS since 2000, BS OHSAS 18001 since 2004, ISO TS 16949 

since 2002 

GETRAG Areal in Ludwigsburg was sold to investors LBW Wealth Management in the summer of 2011 

as part of the restructuring of the company. Since then, GETRAG has hired the production facilities 

to house the hardening shop and for the production of timing gears and components. Hardening and 

mechanical production capacity at this site has been expanded significantly. 


GETRAG Logistics service centre Neuenstadt 

Established in 2004 (in Heilbronn) 

36 employees 

Logistics services and central warehouse 


2005 

area. Furthermore, area-wide walkways will be installed so that production material will be transported 

via dolly trains with trailers as opposed to the previous use of fork lifters. Fortunately, there were no 

masterplan-related work accidents as of yet. 

The logistics services centre of GETRAG coordinates the movement of goods and empties between 

GETRAG and the suppliers. The new site in Neuenstadt has been in use since the end of 2010. The 

logistics centre there has the latest fire protection technology and modern radiant heating system. The 

site lies partly within in a water protection area, resulting in increased requirements on the handling of 

water-hazardous substances. The main environmental impacts stem from the packaging used and the 

energy consumption. 

GETRAG Plant Rosenberg 


534 employees 

Production of manual transmissions 

Certifications: ISO 14001 since 1997, EMAS since 1996, BS OHSAS 18001 since 2004, ISO TS 16949 

since 2002 

GETRAG Plant Neuenstein 

Established in 1975 as Zahnradwerk Neuenstein 

913 employees 

Production of manual, dual clutch and electrical transmissions as well as wheelset components and 

axles 


2002 

In Rosenberg, manual transmissions are even produced using innovative machining technologies 

like power honing, for example. In 2003, a QNPS (Quality Network Production System) was developed 

here and this system is now used for monitoring environmental and occupational health and safety 

performance as well. 

In the past year we faced the technical, organisational, logistical and safety challenge of implementing 

the masterplan restructuring. We succeeded in resetting 200 machines at full load. At the same 

time we handled the integrated construction of a new part to factory hall 2 with a production area of 

about additional 3,000 m² for which we had had to tear down parts of buildings and projecting roofs 

in advance. From now on the entire factory hall 2 A-I has a ventilation zone of 24,000 m² of production 


SITE OBJECTIVES FOR 2012 AND 2013: 

SITE OBJECTIVE SPECIFIC TARGET MEASURE TARGET 

DATE 

Untergruppenbach Reduce CO 2 emissions Develop a method for comparative assessment of 

consumption 

St. Georgen Reduce CO 2 emissions Develop a method for comparative assessment of 

consumption 

Transmissions will be installed in a standardised vehicle environment and will therefore complete 

a standardised driving cycle. Different vehicle environments will be available for different types of 

transmissions and torque classes. 

Transmissions will be installed in a standardised vehicle environment and will therefore complete 

a standardised driving cycle. Different vehicle environments will be available for different types of 

transmissions and torque classes. 

30.06.2012 

30.06.2012 

Neuenstadt Improve legal certainty Verify the environmental performance of service providers Conduct environmental audits on service providers with regard to the cleaning of packaging 31.10.2012 

Improvement regarding 

energy 

Reduce the electricity requirements for lighting 

Develop a concept for using LED lighting in the storage area, taking into account occupational 

health and safety as well as economic aspects 

31.07.2012 

Neuenstein 


fire protection 

Restore the vehicles of our on-site fire service to “state-ofthe-art” 

Purchase a fire truck that can carry 900l of extinguishing agent 31.03.2012 


occupational health and 

safety 


energy and emissions 


occupational health and 

safety 

Reduce the lift truck traffic in halls 2 and 4 Purchase 2 dolly trains, each with 4 trailers 30.06.2012 

Purchase a solar charging station A solar charging station will be installed for an eSmart vehicle 30.09.2012 

Plan walkways in the area of hall 2 There will be extensive marking and labelling of all walkways in hall 2 30.09.2012 

Bad Windsheim 


energy 

Exploit the waste heat from the compressed air generator 

purchased in 2012 

Incorporate the compressed air generator purchased in 2012 into the existing heat recovery system 31.07.2013 

Ludwigsburg 

Conserve energy and 

resources 

Reduce wastewater (drain water) from the DO4 washing 

machine by 20% = from 167.5m³ to 134m³ a year (DO4 = 

pusher-type furnace no. 4) 

Replace/restore the washing machine in DO4 31.09.2012 

Rosenberg 

Reduce the risk of 

contamination 

Straighten and seal the outer surface Apply a seal coat following demolition of the raw parts hall in the inner yard 31.12.2013 

Reduce the risk of 

contamination 

Decommission the cross conveyor in the chip ejection chute 

as part of the restructuring to achieve environment-friendly 

vacuum transfer of chips 

Phase 1 of decommissioning the chip channels Turning/Grinding 31.12.2013 

Reduce emissions 

Reduce CO 2 emissions through energy savings in machinery 

and equipment in the region of 225 t in 2012 

Rationalisation and replacement of machinery and equipment with latest technology (reduction of 

operations) 

31.12.2012 


OBJECTIVES ACHIEVED IN 2011: 

SITE OBJECTIVE SPECIFIC TARGET MEASURE TARGET DATE 


Reduction of indirect 

EHS impact 

Reduction of indirect EHS impact at suppliers’ premises Distribution of the “Principles of Social Responsibility” to suppliers and business partners and 

collection of associated statements. 

31.12.2011 

Improvement of 

the environmental 

awareness of our 

suppliers 

Increase main suppliers certified in accordance with 

ISO 14001 or EMAS to 100%. 

Main suppliers must be certified in accordance with ISO 14001 or EMAS. 31.12.2011 

Neuenstadt 

Improvement 

regarding energy 

Further reduction of storage area in long-term storage 

by at least 10% 

Scrapping of slow-moving material 31.12.2011 

Neuenstein 

Improvement 

regarding water 

Savings in evaporation water and saving of 300,000 kW/ 

year in electricity 

New construction of a central cooling system on the roof of the existing central heating system. 

Erection of a cooling tower on the open space next to central cooling system with new construction of 

a sound insulation wall. 

31.12.2011 

Improvement 


Reduction of compressed air leakages with a saving of 

20,000 euros/year 

Acquisition of an ultrasonic measuring device for locating compressed air leakages and checking all 

systems 

31.12.2011 

Bad Windsheim 

Improvement of 

occupational health 

and safety 

Further reduction of hazardous substances Substitution meetings were held 31.12.2011 

Resource 

conservation 

Reduction of displaced oil volumes and thus the costs 

incurred for fresh oil and disposal 

Optimisation of the layout in terms of oil displacement. Optimisation of check routines/procedures 11.03.2011 

Resource 

conservation 

More efficient use of compressed air Creation of a master plan for compressed air supply for the site 31.10.2011 

Resource 

conservation 

More efficient handling with minimal-volumelubrication 

oils 

CIP (Continuous Improvement Process) project to reduce consumption on minimal-volumelubrication 

systems 

31.12.2011 

Rosenberg 

Improvement 


Reduction of energy consumption (electricity) by 20% in 3 

years, based on the QNPS performance figures for 2008 

Establishment of an energy table 31.12.2011 

Ludwigsburg 

Reduction of 

resources 

Decommissioning of wastewater treatment system Conversion to pick-up and disposal by the company Buster 31.12.2011 

Maintenance of the 

EHS management 

system 

Implementation of the GETRAG EHS management 

system at the new production site in Ludwigsburg 

Transfer of existing processes and procedures to the situations at the new site 31.12.2011 


OBJECTIVES NOT ACHIEVED IN 2011: 

SITE OBJECTIVE SPECIFIC TARGET MEASURE REASON 

Bad Windsheim 

Improvement 


Use of waste heat from the cooling system 

Efficiency audit as to whether the waste heat from the 

cooling machines can be used for basic heating of the 

continuous washing machine in hall 8 

The issue of using waste heat from the cooling 

machines will be re-examined as part of the 

compressed air master plan and its implementation in 

2012 

Reduction 

with respect to 

contamination risk 

Prevention of contamination Creation of a central waste collection station The issue of the waste collection station will be 

re-examined as part of the 2012 concept planning 

regarding the creation of new logistics areas 

Improvement with 

respect to the 

consumption of 

resources 

Prevention of soil sealing 

Use of areas that arise within the framework of a new 

construction measure 

The issue of the waste collection station will be 

re-examined as part of the 2012 concept planning 

regarding the creation of new logistics areas 


Reduction of indirect 

EHS impact 

Reduction of indirect EHS impact at suppliers’ 

premises 

Investigation as to how the “Principles of Social 

Responsibility” may be implemented by suppliers 

Detailed investigations will continue regardless of the 

“Code of Conduct” decision, e.g. with regard to specific 

countries, goods groups, etc. 

One measure will be to examine our three new Asian 

machinery suppliers (Mazak, Doosan and S&T) with 

regard to the social principles. 


INPUT/OUTPUT BALANCE 

INPUT 2011 

Total for GETRAG 

Germany, Italy, 

Mexico 

Total amount for 

Germany 


St. Georgen 

Neuenstadt 

Ludwigsburg 

Neuenstein 

Rosenberg 

Bad Windsheim 

Bari 

Irapuato 

RAW MATERIALS 

Steel 61,939 30,033 due the partially cross-plant production of components at present, site-specific data would be of no t 14,657 17,249 t 

Aluminium 16,843 9,818 use 

t 1,157 5,868 t 

Cast iron 657 t 657 t 

Total 78,782 39,851 t 15,814 23,117 t 

AREA USAGE 

Built area 208,920 140,500 13,980 * 10,000 25,996 46,323 27,924 16,276 m² 29,053 39,367 m² 

AUXILIARY & OPERATING MATERIALS 

Transmission oil 1,104 814 2 0 0 0 469 327 16 m³ 58 232 m³ 

Hydraulic oil 185 48 0 0 0 5 13 14 17 m³ 136 1 m³ 

Hardening oil 57 57 0 0 0 25 33 0 0 m³ 0 0 m³ 

Methanol 506 506 0 0 0 102 404 0 0 m³ 0 0 m³ 

Cutting fluid concentrate 

- water-mixable 190 72 1 0 0 5 24 11 32 m³ 18 100 m³ 

- non-water-mixable 193 193 0 0 0 14 128 44 6 m³ 0 0 m³ 

ENERGY SOURCE 

Electricity 158,343,328 97,953,843 4,456,084 83,028 429,852 9,979,258 42,619,134 22,796,064 17,590,423 kWh 54,385,000 6,004,485 kWh 

Heating oil 573,685 573,685 0 0 0 277,165 197,110 99,410 0 kWh 0 0 kWh 

Natural gas 9,713,406 9,677,850 1,619,421 194,649 236,275 70,995 5,756,346 0 1,800,164 kWh 0 35,556 kWh 

District heating 585,540 585,540 0 0 0 0 0 585,540 0 kWh 0 0 kWh 

Diesel for transmission test rigs 143,160 137,160 22,840 0 0 0 114,320 0 0 kWh 0 6,000 kWh 

Petrol for transmission test rigs 1,510,060 1,510,060 234,360 0 0 0 1,275,700 0 0 kWh 0 0 kWh 

PERCENTAGE OF ENERGY FROM RENEWABLE ENERGY SOURCES 

Percentage for electricity 28 28 24 50 24 24 24 24 24 % * * % 

Percentage for district heating 0 0 0 0 0 0 0 2,5 0 % * * % 

WATER 

Drinking water 211,177 77,688 5,159 284 602 5,456 40,688 15,441 10,058 m³ 106,726 26,763 m³ 

Grey water (rain + groundwater) 3,007 3,007 3,007 0 0 0 0 0 0 m³ 0 0 m³ 


OUTPUT 2011 

Total for GETRAG 

Germany, Italy, 

Mexico 


Germany 


St. Georgen 

Neuenstadt 

Ludwigsburg 

Neuenstein 

Rosenberg 

Bad Windsheim 

Bari 

Irapuato 

PRODUCTS PRODUCED 

Transmissions 1,047,162 609,241 

107,369 330,552 Items 

Axles 12,644 12,644 

due the partially cross-plant production of components at present, 

site-specific data would be of no use 

Items 

0 0 Items 

Components 1,642,530 1,254,889 387,641 0 Items 

Total 2,702,336 1,876,774 495,010 330,552 Items 

WASTE (NOT INCLUDING CONSTRUCTION WASTE) FOR RECYCLING 

non-hazardous waste ** 15,130 5,300 257 6 0 495 1,909 1,822 810 t 7,415 2,415 t 

hazardous waste *** 2,308 1,343 12 0 0 578 405 200 148 t 966 0 t 

FOR DISPOSAL 

non-hazardous waste ** 26 0 0 0 0 0 0 0 0 t 26 0 t 

hazardous waste *** 1,224 1 0 0 0 1 0 0 0 t 307 915 t 

CONSTRUCTION WASTE FOR RECYCLING 

non-hazardous waste ** 62 62 0 0 0 43 16 0 3 t * * t 

hazardous waste *** 6 6 0 0 0 0 6 0 0 t * * t 

FOR DISPOSAL 

non-hazardous waste ** 0 0 0 0 0 0 0 0 0 t * * t 

hazardous waste *** 1 1 0 0 0 0 1 0 0 t * * t 

Radioactive waste (from electricity 

0 0 0 0 0 0 0 0 0 kg * * kg 

generation) 

** including 020204000, 030105000, 101112000, 101203000, 120101000, 120102000, 120103000, 120104000, 120115000, 120117000, 120117001, 120117002, 150101000, 150101001, 150101002, 150102000, 150102001, 150102002, 150102003, 150102004, 150103000, 150106000, 

15107001, 160214000, 160216000, 160604000, 170101000, 170101001,170107001, 160120000, 170107000, 170201001, 170202000, 17401000, 170411000, 170504000, 170504002, 170802000, 170904000, 190904000, 200101000, 200108000, 200136000, 200138000, 200301000, 200301001, 200202000, 

200307000 

*** including 060203000, 060502000, 061302000, 070208000, 070608000, 080111000, 080409000, 110105000, 110107000, 120109000, 12010901, 120110000, 120112000, 120118000, 130105000, 130205000, 130205001, 130502000, 130508000, 130899000, 140603000, 150110000, 

150202000, 15020202, 160601000, 160507000, 160507001, 160507002, 160508000, 160708000, 170204000, 170204001, 200121000, 200123000, 200133000, 200135000, 200135001, 200135002, 170503001, 110302000, 160507000, 170603000 

* no data 

CO 2 EMISSIONS 

Electricity **** 56.839 23.019 1.047 20 101 2,345 10,015 5,357 4,134 t 30,999 2,821 t 

Heating oil 149 149 0 0 47 72 51 26 0 t 0 0 t 

Natural gas 1,943 1,936 324 39 0 14 1,151 0 360 t 0 7 t 

District heating **** 0 0 0 0 0 0 0 0 0 t 0 0 t 

Diesel for transmission test rigs 36 36 6 0 0 0 30 0 0 t 0 0 t 

Petrol for transmission test rigs 347 347 54 0 0 0 293 0 0 t 0 0 t 

Flights 1,141 1,141 Shown only as a total amount, based on 8,228,067 km t * * t 

**** Calculation basis: energy provider’s emission factors (the district heating for the Rosenberg site comes from a biogas plant and is therefore CO2 neutral) 


SF 6 

0 0 0 0 0 0 0 0 0 t * * t 

NOX EMISSIONS 

Natural gas 525 523 87 11 13 4 311 0 97 kg 0 2 kg 

Heating oil 68 68 0 0 0 33 23 12 0 kg 0 0 kg 

CH4 EMISSIONS 

0 0 0 0 0 0 0 0 0 t * * t 

N 2 O 

Hydrofluorocarbon 

Perfluorocarbon 

0 0 0 0 0 0 0 0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

0 0 0 0 0 0 0 0 0 t * * t 

0 0 0 0 0 0 0 0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

0 0 0 0 0 0 0 0 0 t * * t 

0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

0 0 0 0 0 0 0 0 0 t * * t 

0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

0 0 0 0 0 0 0 0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

SO 2 EMISSIONS 



Dust (PM10) 



WASTEWATER 

Production wastewater 67,998 13,934 30 0 0 4.916 7,107 1,028 853 m³ 53,190 874 m³ 

other wastewater (e.g. from sanitary 46,288 33,602 7,468 284 602 540 11,788 7,736 5,184 m³ 7,066 5,620 m³ 

facilities) 


INPUT 2011 

PERFORMANCE FIGURES IN 

RELATION TO TOTAL WEIGHT 

Weghted average 

GETRAG Operations 


Germany 


St. Georgen 

Neuenstadt 

Ludwigsburg 

Neuenstein 

Rosenberg 

Bad Windsheim 

Bari 

Irapuato 

AUXILIARY & OPERATING MATERIALS 

Transmission oil 14 20 0 0 0 0 12 8 0 l/t 4 10 l/t 

Hydraulic oil 2 1 0 0 0 0 0 0 0 l/t 9 0 l/t 

Hardening oil 1 1 0 0 0 1 1 0 0 l/t 0 0 l/t 

Methanol 6 13 0 0 0 3 10 0 0 l/t 0 0 l/t 

Cutting fluid concentrate 

- water-mixable 2 2 0 0 0 0 1 0 1 l/t 1 4 l/t 

- non-water-mixable 2 5 0 0 0 0 3 1 0 l/t 0 0 l/t 

ENERGY SOURCE 

Electricity 2,010 2,458 112 2 11 250 1,069 572 441 kWh/t 3,439 260 kWh/t 

Heating oil 7 14 0 0 0 7 5 2 0 kWh/t 0 0 kWh/t 

Natural gas 123 243 41 5 6 2 144 0 45 kWh/t 0 2 kWh/t 

District heating 7 15 0 0 0 0 0 15 0 kWh/t 0 0 kWh/t 

Diesel for transmission test rigs 2 3 1 0 0 0 3 0 0 kWh/t 0 0 kWh/t 

Petrol for transmission test rigs 19 38 6 0 0 0 32 0 0 kWh/t 0 0 kWh/t 

WATER 

Drinking water 2,681 1,949 129 7 15 137 1,021 387 252 l/t 6.749 1,158 l/t 

Grey water (rain + groundwater) 38 75 75 0 0 0 0 0 0 l/t 0 0 l/t 


OUTPUT 2011 

PERFORMANCE FIGURES IN 

RELATION TO TOTAL WEIGHT 

Weghted average 

GETRAG Operations 


Germany 


St. Georgen 

Neuenstadt 

Ludwigsburg 

Neuenstein 

Rosenberg 

Bad Windsheim 

Bari 

Irapuato 

WASTE (NOT INCLUDING CONSTRUCTION WASTE) FOR RECYCLING 

non-hazardous waste ** 192 133 6 0 0 12 48 46 20 kg/t 469 104 kg/t 

hazardous waste *** 29 34 0 0 0 15 10 5 4 kg/t 61 0 kg/t 

FOR DISPOSAL 

non-hazardous waste ** 0 0 0 0 0 0 0 0 0 kg/t 2 0 kg/t 

hazardous waste *** 16 0 0 0 0 0 0 0 0 kg/t 19 40 kg/t 

CONSTRUCTION WASTE FOR RECYCLING 

non-hazardous waste ** 1 2 0 0 0 1 0 0 0 kg/t * * kg/t 

hazardous waste *** 0 0 0 0 0 0 0 0 0 kg/t * * kg/t 

FOR DISPOSAL 

non-hazardous waste ** 0 0 0 0 0 0 0 0 0 kg/t * * kg/t 

hazardous waste *** 0 0 0 0 0 0 0 0 0 kg/t * * kg/t 

Radioactive waste (from 

electricity generation) 

2 3 0 0 0 0 1 1 1 g/t * * g/t 

** including 020204000, 030105000, 101112000, 101203000, 120101000, 120102000, 120103000, 120104000, 120115000, 120117000, 120117001, 120117002, 150101000, 150101001, 150101002, 150102000, 150102001, 150102002, 150102003, 150102004, 150103000, 150106000, 

15107001, 160214000, 160216000, 160604000, 170101000, 170101001,170107001, 160120000, 170107000, 170201001, 170202000, 17401000, 170411000, 170504000, 170504002, 170802000, 170904000, 190904000, 200101000, 200108000, 200136000, 200138000, 200301000, 

200301001, 200202000, 200307000 

*** including 060203000, 060502000, 061302000, 070208000, 070608000, 080111000, 080409000, 110105000, 110107000, 120109000, 12010901, 120110000, 120112000, 120118000, 130105000, 130205000, 130205001, 130502000, 130508000, 130899000, 140603000, 150110000, 

150202000, 15020202, 160601000, 160507000, 160507001, 160507002, 160508000, 160708000, 170204000, 170204001, 200121000, 200123000, 200133000, 200135000, 200135001, 200135002, 170503001, 110302000, 160507000, 170603000 

CO 2 EMISSIONS 

Electricity **** 721 578 26 0 3 59 251 134 104 kg/t 1.960 122 kg/t 

Heating oil 2 4 0 0 0 2 1 1 0 kg/t 0 0 kg/t 

Natural gas 25 49 8 1 1 0 29 0 9 kg/t 0 0 kg/t 

District heating **** 0 0 0 0 0 0 0 0 0 kg/t 0 0 kg/t 

Diesel for transmission test rigs 0 1 0 0 0 0 1 0 0 kg/t 0 0 kg/t 

Petrol for transmission test rigs 4 9 1 0 0 0 7 0 0 kg/t 0 0 kg/t 

Flights 14 29 Shown only as a total amount, based on 8,228,067 km kg/t * * kg/t 

**** Calculation basis: energy provider’s emission factors (the district heating for the Rosenberg site comes from a biogas plant and is therefore CO2 neutral) 


SF 6 

0 0 0 0 0 0 0 0 0 t/t * * t/t 

NOx EMISSIONS 

Natural gas 6 13 2 0 0 0 8 0 2 g/t 0 0 g/t 

Heating oil 1 2 0 0 0 1 1 0 0 g/t 0 0 g/t 

CH 4 

EMISSIONS 

0 0 0 0 0 0 0 0 0 t/t * * t/t 

N 2 O 

Hydrofluorocarbon 

Perfluorocarbon 

0 0 0 0 0 0 0 0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

0 0 0 0 0 0 0 0 0 t/t * * t/t 

0 0 0 0 0 0 0 0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

0 0 0 0 0 0 0 0 0 t/t * * t/t 

0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

0 0 0 0 0 0 0 0 0 t/t * * t/t 

0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

0 0 0 0 0 0 0 0 0 t CO 2 

equivalent 

* * t CO 2 

equivalent 

SO 2 EMISSIONS 

Natural gas 0 0 0 0 0 0 0 0 0 g/t 0 0 g/t 

Heating oil 1 2 0 0 0 1 1 0 0 g/t 0 0 g/t 

Dust (PM10) 

Natural gas 44 87 15 2 2 1 52 0 16 mg/t 0 1 mg/t 

Heating oil 5 10 0 0 0 5 4 2 0 mg/t 0 0 mg/t 

WASTEWATER 

Production wastewater 863 350 1 0 0 123 178 26 21 l/t 3.363 38 l/t 

other wastewater (e.g. from sanitary 

facilities) 

588 843 187 7 15 14 296 194 130 l/t 447 243 l/t 


VALIDATION: 

In the period from 12/03/2012 to 30/03/2012, I, the 

Dr. Hans-Peter Wruk 

Environmental auditor 

Im Stook 12 

25421 Pinneberg 

Registration number: D-V-00051 

on behalf of the following sites/companies (GETRAG Germany): 

Based on the site appraisals I have conducted and inspection of the data and information presented, 

it is confirmed that the environmental policy, the environmental programme, the environmental 

management system, the environmental review process (or environmental audit procedure) and the 

following chapters 

Chapter 1: Companies in general 

Chapter 2: Strategy and management 

Chapter 4: Environmental protection 

Chapter 5: Product stewardship, with limitation to the following sections 

- Environment-friendly process 

- Planning 

GETRAG Getriebe- und Zahnradfabrik 

Hermann Hagenmeyer GmbH & Cie KG 

Hermann-Hagenmeyer-Straße74199 


GETRAG Logistik Dienstleistungszentrum 

Wilhelm-Maybach-Straße 10a 

74196 Neuenstadt a. 

Bad Windsheim site 

Burgbernheimer Straße 5 

91438 Bad Windsheim 

- Mechanical production 

- Heat treatment 

- Assembly 


Hermann-Hagenmeyer-Straße 74199 


St. Georgen site 

Industriestraße 5 

78112 St. Georgen 

Rosenberg site 


74749 Rosenberg 

Neuenstein site 

Hermann-Hagenmeyer-Straße 

74632 Neuenstein 

Ludwigsburg site 


71636 Ludwigsburg 

have checked for fulfillment of the requirements of the Regulation (EC) No. 1221/2009 of the European 

Parliament and of the Council of 25 November 2009 (Title: on the voluntary participation by organisations in 

a Community eco-management and audit scheme, repealing Regulation (EC) No. 761/2001 and Commission 

Decisions 2001/681/EC and 2006/193/EC), in the version dated 22/12/2009. 

- Transmission recycling 

In the appendix 

- Our sites and their sustainability objectives for 2012 

- Input/Output Balance 

of this sustainability report of the sites/companies indicated meet the requirements of the Regulation (EC) 

No. 1221/2009; 

it is confirmed that the statements in this sustainability report in the aforementioned chapters of the sites/ 

companies indicated are reliable and that the relevant environmental issues are adequately considered 

therein; 

the aforementioned chapters of this sustainability report are declared valid. 

Untergruppenbach, 30/03/2012 

Dr. Hans-Peter Wruk 

Environmental auditor 


FULFILLMENT OF GRI-CRITERIA 

1. Strategy and analysis 

standard disclosures part i: profile 

PROFILE DESCRIPTION PAGE STATUS 

1,1 

Statement from the most senior decision-maker of the 

organisation. 

03 

1,2 Description of key impacts, risks and opportunities 12 

2. Organisational profile 


2,1 Name of the organisation. 6 

2,2 Primary brands, products and/or services. 7 

2,3 

Organisational structure, including the main divisions, the 

various operating companies, subsidiaries and joint ventures. 

8-9 

2,4 Headquarters of the organisation. 6 

2,5 

Number of countries in which the organisation operates and 

names of the countries in which the main operating companies 

are based or that are specifically relevant to the sustainability 

9, 36 

issues covered in the report. 

2,6 Ownership structure and legal form. 36 

2,7 

Markets served (including a geographical breakdown, sectors 

served and customer structure). 

36 

2,8 Scale of the reporting organisation. 6 

2,9 

Significant changes in the size, structure of ownership during 

the reporting period. 

6 

2,10 Awards received in the reporting period. none 

3. Report parameters 


3,1 

Reporting period (e.g. fiscal/calendar year) for the information 

contained in the report. 

36 

3,2 Publication of most recent report, if any. 36 

3,3 Reporting cycle (annual, biennial, etc.). 36 

3,4 Contact point for questions regarding the report or its contents. 2 

3,5 Process for defining report content. 36 

3,6 

Boundary of the report (e.g. countries, divisions, subsidiaries, 

leased facilities, joint ventures, suppliers). See GRI Boundary 

Protocol for further information in this regard. 

36 


3,7 

State any specific limitations on the scope or boundary of the 

report (see notes on the completeness principle for explanation 36 

of scope). 

3,8 

Basis for reporting on joint ventures, subsidiaries, leased 

facilities, outsourced operations and other entities that can 

significantly affect comparability of the reporting periods or of 

the information for various organisations. 

36 

3,10 

3,11 

Explain the effects of any re-statements of information provided 

in earlier reports and the reasons for such re-statement (e.g. 

mergers/acquisitions, change of base years/periods, nature of 

business, measurement methods). 

Significant changes from previous reporting periods in the 

scope, boundary, or measurement methods applied in the 

report. 

4. Governance, Commitments and Engagement 

4,1 

4,2 

4,3 

4,4 

4,8 

4,11 

Here, corporate governance means the management structure 

of the organisation. 

This includes committees under the highest governance body 

that are responsible for specific tasks, such as setting strategy 

or organisational oversight. 

Indicate whether the Chair of the highest governance body is 

also an executive officer. 

For organisations without a supervisory board, state the 

number of members of the highest governance body that are 

independent or non-members of the executive board. 

Mechanisms for shareholders and employees to provide 

recommendations or direction to the highest governance body. 

Internally-developed mission statements, internal codes of 

conduct and principles that determine and control economic, 

environmental, and social performance, including relevant risks 

and opportunities as well as compliance with internationally 

agreed standards, codes of conduct and principles. 

Explanation of whether and how the precautionary approach or 

principle is addressed by the organisation 

4,14 List of stakeholder groups engaged by the organisation. 36 

4,15 Basis for selection of the stakeholders with whom to engage. 36 

4,16 

Approaches to stakeholder engagement, including frequency of 

engagement by type and by stakeholder group. 36 

First 

report 

of this 

type 

First 

report 

of this 

type 

36 

36 

36 

36 

11, 12, 

14, 15 

22 

50 PUTTING THE PIECES TOGETHER 

- fully covered - partly covered

STANDARD DISCLOSURES PART III: PERFORMANCE INDICATORS 

Economic performance indicators 

INDICATORS DESCRIPTION PAGE STATUS 

Economic performance 

EC1 

Direct economic value generated and distributed, including revenues, 

operating costs, employee compensation, donations and 

other community investments, retained earnings and payments 

to capital providers and governments (taxation). 

Environmental performance indicators 


Materials 

EN1 Materials used by weight or volume. 43-48 

Energy 

EN3 

Direct energy consumption by primary energy source. 22, 43- 

48 

EN4 

Indirect energy consumption by primary energy source. 22, 43- 

48 

EN5 

Energy saved due to conservation and efficiency improvements. 22, 43- 

48 

EN6 

EN7 

Water 

EN8 

Initiatives to provide energy-efficient or renewable energy based 

products, and reductions in energy requirements as a result of 

these initiatives. 

Initiatives to reduce indirect energy consumption and the 

reductions achieved. 

6 

22, 43- 

48 

22, 43- 

48 

Total water withdrawal by source. 22, 43- 

48 

Biodiversity 

Location and size of land in or adjacent to protected areas. 

EN11 

Location and size of land of high biodiversity value outside or 

adjacent to protected areas. 

Emissions, wastewater and waste 

EN16 

EN17 

EN18 

EN20 

22, 38- 

39 

Total direct and indirect greenhouse gas emissions by weight. 23, 43- 

48 

Other relevant greenhouse gas emissions by weight. 23, 43- 

48 

Initiatives to reduce greenhouse gas emissions and the 

reductions achieved. 

23, 43- 

48 

NOx, SOx and other significant air emissions by type and weight. 23, 43- 

48 

EN21 

EN22 

EN23 

Total wastewater discharge by type and place of discharge. 23, 43- 

48 

Total weight of waste by type and disposal method. 23, 43- 

48 

Total number and volume of significant spills. 23, 43- 

48 

Weight of transported, imported, exported or treated waste 

deemed hazardous under the terms of the Basel Convention, 

EN24 

Annexes I/II/III & VIII, and percentage of transported waste 

shipped internationally 

Products and services 

Initiatives to mitigate the environmental impacts of products and 

EN26 

services and extent of impact mitigation. 

Transport 

Significant environmental impacts of transporting products 

EN29 

and other goods and materials used for the organisation‘s 

operations, and transporting members of the workforce. 

23, 43- 

48 

22, 43- 

48 

43-48 

Social performance indicators: Labour practices & decent work 


Employment 

LA1 

Total workforce by employment type, employment contract and 

region. 

6 

LA2 

Total number and rate of employee turnover by age group, 

gender and region. 

17 

Occupational health and safety 

LA7 

Injuries, occupational diseases, lost days and absenteeism as 

well as number of work-related fatalities by region. 

18 

LA8 

Education, training, counselling, prevention and risk-control 

programs in place to assist workforce members, their families 17-19 

or community members regarding serious diseases. 

Training and education 

Programs for skills management and lifelong learning that 

LA11 

support the continued employability of employees and assist 17-19 

them in managing career endings. 

Diversity and equal opportunity 

Composition of governance bodies and breakdown of employees 

LA13 

per category according to gender, age group, minority group 17 

membership & other indicators of diversity. 

Customer health and safety 

PR1 

Life cycle stages in which the health and safety impact 

of products or services on customers are assessed for 

improvement, and percentage of significant products and 

services categories subject to such procedures. 

22, 

25-29

PUTTING THE PIECES TOGETHER - Getrag

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