Internship Report in safety industry

1. 1
INTERNSHIP REPORT
Internship in the area of Safety and Energy Management system
Internship report by
Name: Haris Ahmed
Martikel nummer: 378175
Internship Supervisor: Mr. Friedrich Prossegger
Course Name: Process, Energy and Environmental Systems
Engineering
Course Supervisor: Prof.Dr. Tatiana Morozyuk

2. 2
Table of Contents
1 Introduction 4
1.1 About Company 4
1.2 Continental is structured in five divisions 4
1.3 Chassis and Safety Division 5
1.4 Advanced Driver Assistance Systems, ADAS at Lindau, Bayern 5
1.5 Department Infrastructure (Safety and Energy Department) 6
2 Tasks and Activities 6
2.1 Safty Management System 6
2.1.1 Training of Software 6
2.1.2 Gathering Information for Chemicals 7
2.1.3 Updating it in a Hasuma Software 7
2.1.4 Controlling Safety Management System 7
2.1.5 Conclusion 9
2.2 Energy Management System 9
2.2.1 Energy Consumption 9
2.2.2 CO2 Emission 11
2.2.3 Conclusion 11
2.3 Other Tasks 11
2.3.1 Administrative tasks 11
2.3.2 Safety Exhibition 12
2.3.3 Safety Drill 12
2.3.4 Continental Running Day 12
3 Conlcusion 12
Apendixes 13
Apendixes 14
4 References 15
5 Original Internship certificate 16

3. 3
List of Figures
Figure 1: Continental’s AG global locations 4
Figure 2: Continental ADAS Products 5
Figure 3: Hasuma (Hazardous Management System) 6
Figure 4: Hazardous substance management implementation method 8
Figure 5: Monthly energy costs 13
Figure 6: Yearly CO2 Emission table 14
Figure 7: Energy Consumption History 14
Figure 8: Main Energy Consumption Sources 15
Graph 1: Electricity Consumption in KWh 10
Graph 2: Gas Consumption in KWh 10
Graph 3: Amount of CO2 emitted per person 11

4. 4
1 Introduction:
As a student of Process, Energy and Environmental Systems Engineering, I had an
opportunity to do my compulsory internship in various field or direction. As my interest was
in the field of energy management system or safety management System, I luckily got
opportunity to do my internship in both Areas in a company called “Continental AG”. I did
my Internship at ADAS Continental at Lindau am Bodensee, Bayern.
I started my internship on 16-08-2017 and ended it after three months on 25-10-2017.
During my three-month internship I got two supervisors, one was Mr. Andreas Reiter, who
was in charge of giving me tasks plus instructions. He is working there as a safety engineer
and other was Mr. Friedrich Prosseggor , who was my main boss and was responsible of
giving me tasks on energy management systems.
My internship had two phases, in the first phase I had to complete my tasks related to Safety
Management systems and the second phase revolve around Energy Management Systems.
In the following report, I will give more details about my tasks and activities.
1.1 About Company:
Continental AG, commonly known as Continental, is a
leading German automotive manufacturing company specializing in tires, brake systems,
interior electronics, automotive safety, powertrain and chassis components, tachographs,
and other parts for the automotive and transportation industries
Figure 1: Continental AG global locations
1.2 Continental is structured in five divisions:
 Chassis and Safety
 Powertrain
 Interior
 Tyres
 ContiTech

5. 5
One of Continental's main areas of expertise and technological leadership is fuel
consumption reduction, achieved through more efficient fuel injection systems, reduced
rolling-resistance tyres, and hybrid propulsion systems.
1.3 Chassis and Safety Division:
The Chassis & Safety division develops and produces integrated active and passive driving
safety technologies as well as products that support vehicle dynamics. The product portfolio
ranges from electronic and hydraulic brake and chassis control systems to sensors, advanced
driver assistance systems, airbag electronics and sensorics as well as electronic air
suspension systems all the way to windscreen washer systems and headlight cleaning
nozzles.
There are further four division within Chassis and safety Division of Continental AG that are
 Advanced Driver Assistance Systems, ADAS
 Hydraulic Brake Systems, HBS
 Passive Safety Sensorics, PSS
 Vehicle Dynamics, VED
1.4 Advanced Driver Assistance Systems, ADAS at Lindau, Bayern:
Advanced driver-assistance systems, or ADAS, are
systems to help the driver in the driving process.
When designed with a safe human-machine interface,
They should increase car safety and more generally
Road safety.
The ADAS Continental had multiple units at different
Locations.
Lindau – Head office ADAS, Ulm, Riemerling and
Memmingen.
Figure 2: Continental ADAS Products

6. 6
1.5 Department: Infrastructure (Safety and Energy Department)
The department infrastructure was headed by Mr.Friedrch Prosegger and under its controls
there are administration department, Health Safety and environment department (HSE) and
Energy Departments of all the facilities or company units.
2 Tasks and Activities:
My Tasks and Activities are divided into two parts. The First five weeks of my internship, I
was given task to update and control all the hazardous chemicals at in Lindau, Ulm,
Memmingen and Riemerling.
The last five weeks, I have to update and make an automated Energy Management system
for plant unit at Lindau, Ulm, Memmingen and Riemerling.
2.1 Safety Management System
The Management of continental AG had decided to control and document all the hazardous
chemicals .Therefore, they started hiring people for the implementation. Then, a new
department was created with special tasks that controls all the safety engineers throughout
all the divisions of the company.
The company then introduced Online Hazardous substance management system (Hasuma)
into their system. It’s an online software and tool which give information of all the chemical
available in the facility as well as amount, safety hazards, way of stocking and disposing off.
The safety management task had following timeline,
2.1.1 Training of software
In the first week of internship I had a training of the software, that how to use the software
and kind of information is required to complete the task. The Software was user friendly and
was easily to learn. Following is the look of its first page,
Figure 3: Hasuma Hazardous substance management system

7. 7
2.1.2 Gathering Information for the Chemicals:
Information of available chemical which are being used in the company in all the facilities
including Lindau, Ulm, Memmingen and Riemerling had carried out by me. I had collected
the safety data sheets of all the chemicals in the pdf form.
The safety data sheets of the chemicals, which were unavailable I had to request to the
supplier for its data sheets.
2.1.3 Updating it in a Hasuma Software:
After collecting all the safety Data sheets of the chemicals, which we are using at all the
facilities I have to update the chemical in the Hasuma system.
I have to create a following data of each chemical inside the Hasuma system
o Name of chemical
o Amount
o Place and department
o Person Responsible
o Category of chemical
o How to dispose
o Safety data sheets
Once I have created a request of chemical in Hasuma System, this request goes to
authorized person and then to safety engineer for approval. If it is approved then that
specific Chemical has been controlled inside the Hasuma system.
2.1.4 Controlling Safety Management System
The Task was not only to gather data and update the Hasuma software but it also involves
around the safety procedures for storing, using, ordering and disposing off of each specific
chemicals.
We have implemented Hazards management system at all the facilities of the company,
which comprises of following method as shown in the figure,

8. 8
Figure 4: Hazardous substance management implementation method
The best way to protect workers is to remove or eliminate the hazard from the workplace
using the following hazard control methods:
Substitution. Substitute dangerous chemicals, equipment or work methods with safer and
less hazardous ones to eliminate the hazard altogether.
Engineering Controls. Engineering controls are used to make changes to the work
environment, machine or piece of equipment, often reducing the hazard at the
source. Example: Exhaust ventilation can be used to remove a harmful substance such as
carbon dioxide (dry ice) from the air.
Work Practice and/or Administrative Controls. Work practice controls change the way
workers do their jobs to reduce exposure to hazards. Administrative controls address how
the work is structured, such as work pace and break. Example: Rotating workers to reduce
the amount of time they are exposed to the hazard and providing training.
Personal Protective Equipment (PPE). PPE is the least effective way to protect workers from
workplace hazards because if the equipment fails, workers are exposed to the hazard. PPE
includes respirators, face and eye protection, hearing protection, gloves, and protective
clothing

9. 9
2.1.5 Conclusion
All the chemicals are successfully sorted and the Hazardous Chemicals are properly labeled
with safety instruction of usage.
2.2 Energy Management System
The second part of my internship was working on Energy Management System within
company. This Task was specifically focused on Automatic Update of Energy Data of the
company.
Energy management systems can also provide metering, sub metering, and monitoring
functions that allow facility and building managers to gather data and insight that allows
them to make more informed decisions about energy activities across their sites.
The term Energy Management System can also refer to a computer system which is designed
specifically for the automated control and monitoring of those electromechanical facilities in
a building which yield significant energy consumption such as heating, ventilation and
lighting installations.
Most of these energy management systems also provide facilities for the reading of
electricity, gas and water meters. The data obtained from these can then be used to perform
self-diagnostic and optimization routines on a frequent basis and to produce trend analysis
and annual consumption forecasts. [2]
2.2.1 Energy consumption
An energy management system (EMS) is a system of computer-aided tools used by operators
of electric utility grids to monitor, control, and optimize the performance of
the generation and/or transmission system. Also, it could be used in small scale systems like
micro grids.
The ADAS Lindau had designed their Energy management system (EMS) on excel and I was
told by my boss to further automate and eliminate the unrequired Data from the excel file,
the excel file was not that simple, it includes Macros from Visual Basic (VBA) Excel tool.

10. 10
The Energy consumption of the company are shown below in the graphs
Graph 1: Electricity Consumption in KWh
And the gas consumption us following,
Graph 2: Gas Consumption in KWh
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
4000000
4500000
2011 2012 2013 2014 2015 2016 2017
StromKWh
Strom-verbrauch
Strom kWh Memmingerberg
Strom kWh Riemerling
Strom kWh Ulm
Strom kWh Lindau
0
50000
100000
150000
200000
250000
300000
350000
2011 2012 2013 2014 2015 2016 2017
Erdgas Verbrauch
Erdgas kWh

11. 11
2.2.2 CO2 Emission
The Company Continental Ag has a goal of reducing 25% CO2 emission by the year 2020. The
company is growing rapidly and they are hiring number of employees and constructing new
buildings for the employees and that will eventually increase the amount of CO2 they will
produce.
The Task was to automate the data in an excel file so that they can forecast the amount CO2
is produced per employees should be 25% reduced by 2020.
Following is the graph of amount of CO2 (tons) is emitted per person,
Graph 3: Amount of CO2 (Tons) is emitted per person
2.2.3 Conclusion
The Management of Continental AG had a plan to install new meters for electricity, Gas and
water at all companies (facilities). They wanted an Automated Energy Management system
should be ready before the installation of new Meters of electricity, gas and water.
The main reasons were is to forecast the amount of energy will be consumed in the future
and to develop possible ways to reduce the consumption. The second reason was to have
automated energy management system in excel file with new meters so that they can
calculate and view the graphs easily even after the installation of new Meters.
2.3 Other Tasks
Doing an internship in Multinational Company doesn’t means to work all the time on a
specific tasks, one has to be versatile and ready to work on different fields.
As my boss was also a manager of administration department, then he asked me to help out
my other colleagues of administration department with their tasks.
2.3.1 Administrative tasks
The Administrative tasks were to update the data of employees as well as respective
departments within in a company.
0,00
0,50
1,00
1,50
2,00
2,50
3,00
2011 2012 2013 2014 2015 2016
je Mitarbeiter

12. 12
2.3.2 Safety Exhibition
During my internship period, there was big safety exhibition in Dusseldorf called “A+A” . The
boss of the Safety department asked me that if I would like to come with him to the
exhibition. That’s how , I joined them for 3 days trip and had a really erudite time and took
as learning opportunity with my colleagues.
2.3.3 Safety Drill
In the 2nd of my joining as an intern, I was trained and further helped out my colleagues of
the safety department with the organizing of safety drill.
2.3.4 Continental Running Day
The administration department of continental organizes Running Day for continental
employees every year around September for charity purposes. I helped them out with the
association and management of that day.
3 Conclusion
The internship with Continental AG proved really fruitful for me. I learnt different and new
concepts related to the Energy and Safety field. The internship has met all the objectives and
its success has surpassed my expectations. It has opened my eyes to working Professional
life, enlightened me socially, and matured me in a German professional culture. It has
strengthened my knowledge base. Finally, it has given me a clear sense of direction in my
future studies and career as an engineer.

13. 13
Appendix
Figure 5: Monthly energy costs
JanuarFebruarMärzAprilMaiJuniJuliAugustSeptemberOktoberNovemberDezemberGesamt
Lindau240002400024000240002400024000240002400024000216.000,00€
LindauNetznutzung78007800780078007800780078007800780070.200,00€
UlmLM1061006100610061006100610061006100610054.900,00€
UlmLM159009009009009009009009009008.100,00€
UlmGlacisBastion
Riemerling3653653653653653653653653653.285,00€
Memmingerberg1701701701701701701701701701.530,00€
Gesamt393353933539335393353933539335393353933539335000354.015,00€
LindauGeb.14104104104104104104104104103.690,00€
LindauGeb.38758758758758758758758758757.875,00€
LindauGeb.43203203203203203203203203202.880,00€
Lindaugesamt16051605160516051605160516051605160514.445,00€
UlmLM108008008008008008008008008007.200,00€
UlmLM15505050505050505050600,00€
UlmGlacisBastion
RiemerlingNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-Abr0,00€
Gesamt24552455245524552455245524552455245522.095,00€
Lindau1010101010101010101010101010101010109.090,00€
RiemerlingNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-Abr0,00€
0,00€
Gesamt1010101010101010101010101010101010100009.090,00€
UlmLM1030003000300030003000300030003000300027.000,00€
UlmLM15NK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-AbrNK-Abr0,00€
UlmLM1030003000300030003000300030003000300027.000,00€
UlmLM15333,34333,34333,34333,34333,34333,34333,34333,34333,344.000,00€
Diesel364780617208113117434103001102910619821677.825,00€
DieselStromaggregat213839415130127409021814157673117.506,00€
Super34076286687391337029556758887379867160.233,00€
571.764,00€Gesamt€
Strom
Wasser
Kraftstoffe
Erdgas
Fernkälte
Fernwärme

14. 14
Figure 6 : Yearly CO2 Emission table
Figure 6 : Source (Jährliche CO2 Emissionen 2017)
Figure 7: Energy Consumption History
Figure 7 : Source (Energiemengen Standorte Lindau, Ulm, Memmingerberg und Riemerling seit 2011)
Menge CO2-
Emissionen (t)
Lindau 2205587 0,00
Ulm 782102 0,00
Riemerling 81998 20,55
Memmingerberg 15613 0,00
Lindau 2993974 0,00
Ulm 796 0,00
Riemerling 0 0,00
Memmingerberg 17 0,00
Lindau 28273549 5733,50
Riemerling 0 0,00
Fernwärme kWh Ulm 113000 11,19
Diesel 844888 227,44
Diesel Aggreg. Li 345720 93,06
Super 520231 138,12
Kältemittel kg 0 0,00
6223,85Gesamt
Energieträger
Kraftstoffe kWh
(1l = 10kWh)
Wasser m³
Erdgas kWh
Strom kWh
2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Lindau 1274359 1422686 1416252 1624952 2126817 2652920 2205587
Ulm 1118212 625205 976667 1135158 782102
Riemerling kein Zähler kein Zähler kein Zähler 70992 94601 81998
Memmingerberg kein Zähler 15613
Gesamt 1274359 1422686 2534464 2250157 3174476 3882679 3085300
Lindau 2651 2778 3131 3298 3538 4459 2993974
Ulm 1956 2319 1039 2002 796
Riemerling kein Zähler kein Zähler kein Zähler kein Zähler kein Zähler 0
Gesamt 2651 2778 5087 5617 4577 6461 2994770
Lindau PD 294476 314194 247722 246856 301298 294135 28273549
Riemerling kein Zähler kein Zähler 0
Ulm 752724 487863 336488 284506 113000
Ulm 866663 714396 475348 577434 401537
Diesel 725770 876780 889770 1407281 1345524 998869 844888
Diesel Aggreg. Li 299390 345720
Super 729800 721810 447540 955318 1101595 845654 520231
Fernwärme kWh
Fernkälte kWh
Kraftstoffe kWh
Erdgas kWh
Strom kWh
Wasser m³

15. 15
Figure 8 : Main Energy Consumption Sources
4 References
[2] https://en.wikipedia.org/wiki/Energy_management_system
[1] https://www.continental-corporation.com/de
EnergieStandortVerbraucher
Energieverbrauch
(kWh)
CO2-
Emissionen(t)
Kosten(€)
1.Serverräumederzeitnichtmessbar
2.Kühlungderzeitnichtmessbar
3.Küchederzeitnichtmessbar
1.Be-/EntlüftungsanlagekeineigenerZähler0,00NK-Abrechnung
2.USVLüftung2782120,00NK-Abrechnung
3.Umweltlab1289390,00NK-Abrechnung
4.LüftungUSV1005800,00NK-Abrechnung
ErdgasLindauHeizungsanlage28273549,315733,509.090,00€
1.Heizkörper11300011,19NK-Abrechnung
2.Serverraum23056025,36NK-Abrechnung
3.Umweltlab9487310,44NK-Abrechnung
alleFuhrpark844888227,4477.825€
StromaggregatLindau34572093,0617.506€
SuperalleFuhrpark520231138,1260.233€
Diesel
Strom
Fernwärme
Fernkälte
Lindau
Ulm
Ulm