annual report - FIAT SpA

1234yf is a fluid and has different properties to R134a, which is a gas, including a lower refrigerant capacity,
requiring optimization of the air-conditioning unit, and is highly flammable, necessitating a review of all system
components and evaluation of the impacts on the work environment and filling systems.
Advanced vehicles, materials and processes
A central objective is to improve the eco-sustainability of vehicles and manufacturing process through the development
of economically sustainable solutions for products and processes. This objective is shared at European level through
the Green Cars Initiative, in which CRF participates actively as a member of the Industrial Advisory Group.
The most significant achievements in this area during 2010 include:
� Iveco Glider. This concept vehicle, presented by Iveco at the 2010 IAA International Motor Show in Hanover, is
the fruit of a creative collaboration between Iveco and CRF. It is a new vehicle concept that offers high productivity
and low environmental impact. The project focused on two key elements: energy efficiency and on-board comfort
and functionality. In terms of energy efficiency, researchers developed a Kinetic Energy Recovery System (KERS),
which enables the recovery of kinetic energy that would otherwise be dissipated as heat during braking, in addition
to a thermodynamic system based on a Rankine cycle that recovers heat from the engine that would otherwise be
dispersed through the exhaust and radiator. The Glider also generates renewable energy on-board using highly
efficient and flexible solar panels that take up approximately 2 square meters on the roof of the cab and are
capable of producing up to 2kWh of energy. Finally, any excess electric energy not used by the auxiliary systems is
stored in an Auxiliary Energy Unit for use as an energy source when the vehicle is stationary. Research into
significantly reducing aerodynamic drag, the use of new on-board energy management systems and the adoption
of heat exchangers and low rolling resistance tires also contributed to the dramatic reduction in consumption and
emissions. With regard to on-board comfort and functionality, the Glider was designed around the driver's specific
needs with the cabin containing the latest technological solutions in terms of ergonomics, infomobility, lighting,
climate control and space management.
� Eco-compatible and recycled materials. In 2010, CRF further increased its commitment to solutions which
address the environmental impacts (including CO2 emissions) from plastic components used in vehicles. Tests
were carried out with biopolymer matrix compounds and recycled end-of-life materials reinforced with micronized
natural fibers to enhance their structural characteristics, while also improving aesthetics.
At the same time, CRF continued to monitor the percentage of recycled materials utilized in the Group's vehicles,
increasing their use, particularly in non-aesthetic areas such as acoustic insulation. In 2010, analysis also
continued into the impacts on the automotive sector of general environmental regulations, such as Classification
Labelling & Packaging (CLP) and Registration Evaluation Authorisation and Restriction of Chemicals (REACH).
For the second of these two regulations an investigation was conducted on Substances of Very High Concern
(SVHCs) whose use may be restricted over the next few years. Alternatives are being tested for all SVHC
materials currently used in the Group's vehicles. Finally, Life Cycle Assessments (LCAs) were conducted to
evaluate the environmental impacts of the new fluid refrigerant HFO 1234yf throughout its entire lifecycle,
comparing it with R134A and with CO2, and of phosphatization processes that could serve as alternatives to the
current process based on nanocomposites derived from zirconium salts.
� Highly energy-efficient production processes. In 2010, CRF continued with the Green Factories project. During
the year, numerous activities focused on improvements in the energy efficiency of manufacturing processes. The
most important of these projects were conducted at Fiat Group Automobiles' Cassino and Mirafiori plants and
focused on development of kinetic energy recovery systems for industrial robots and testing of pilot installations of
highly efficient lighting systems that provide increased light levels with reduced energy consumption. Measures to
improve existing processes continued with the definition of a methodology to reduce energy consumed by
mechanical processes. This area was also addressed by the FlexMech project, through the development of
innovative down-sized, energy-saving actuators for application on machine tools. CRF also began development of
methods and tools for the classification of industrial buildings by energy class to highlight their level of energy
efficiency. In the area of environmental and economic sustainability, CRF participated in the Industrial Advisory
Group of the European Factories of the Future initiative as team leader for development of a multi-year program on
Sustainable Manufacturing, considered of primary strategic importance for the competitiveness of European
manufacturing.
� Micro and nanotechnologies for plant safety In the area of plant safety, Legislative Decree 81/2008 (health and
safety in the workplace) introduced the obligation for employers to assess the risk of exposure to artificial optical
radiation (AOR) for the first time in Italy. With more than a decade of experience in assessing display optics and
new lighting sources, through its New Materials Scouting group, CRF was the first company to begin monitoring
AOR levels at FGA's Mirafiori plant at the end of 2008 and is now the leader in optical radiation assessment,
having conducted tests at more than 15 Fiat Group plants throughout Italy. This activity was necessary to comply
with the legal obligation to assess the risk, but also contributed to a significant reduction in the risk of exposure to
potentially hazardous sources in the factory and to improving the quality of the work environment.
Report on Operations Research and Innovation
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