Supply chain and manufacturing

Commitment to quality

Every day, Gemalto’s solutions and software allow hundreds of millions of consumers to manage their digital services safe in the knowledge that they are secure. Our customers rely on these products to protect revenues, keep data and buildings secure, and to confirm identity to combat fraud. So it is imperative we operate with the highest levels of quality to ensure we deliver totally reliable services.

In 2009, we merged our teams delivering Quality, Security, Health, Safety and Environment together with our World Class Manufacturing organization. This is now one single unit dedicated to improving customer satisfaction, protecting Gemalto employees and stakeholders, improving quality and anticipating new regulations and standards to ensure Gemalto is always compliant with best practice.

As well as the obvious synergies, this single unit has helped us continue the development of a Lean Six Sigma culture. Our World Class Manufacturing approach has evolved and we are now committed to World Class Enterprise. This continues to contribute to the enhancement of our customer relationships and provides tangible benefits to the Company performance.

Environmental management

Efficient, effective manufacturing processes and responsive supply chain management are critical to Gemalto’s success as a global leader in digital security solutions. But as well as satisfying our customers’ needs, we need to be sensitive to the world around us. By managing our environmental impact, we can help secure our industry’s future. This isn’t a recent fad for Gemalto: we have audited our Environment Management System (EMS) for more than ten years now. Twenty-one of our facilities are ISO 14001 certified.

Cleaner manufacturing

Our commitment goes beyond regulatory compliance. For many years, our production facilities have focused on reducing their consumption of energy, water and hazardous materials. For example, in Shanghai, modified air conditioning has reduced energy consumption by 20%. In Singapore, a new design of pallet reduced transport weight by 25%. Overall, paper consumption at our facilities in Gemenos and La Ciotat has fallen by 56%. In the US, our PVC waste is collected and recycled to produce masts for boats. At Tczew in Poland, waste re-used, recycled, or converted to energy has increased from 41% in 2004 to 68% in 2008.

Gemalto's headquarters

Gemalto's certifications

– ISO 9001 (Quality): 27 sites
– ISO 14001 (Environment): 21 sites
– OHSAS 18001 (Health & Safety): 13 sites
– ISO 27001 (Security): 6 sites

Certified Carbon Neutral

Carbon neutral

In 2009 we produced about 9 million cards under the carbon neutral initiative, nearly double our 2008 figure.

Our carbon footprint

Gemalto is a pioneer in CO2 emissions, and we measure the entire Company’s carbon footprint. In 2006, our Fareham facility in the UK was audited as carbon neutral by KPMG. We were the first card manufacturer in the world having a CarbonNeutral® offer. In 2008, we produced 4.7 million cards under the initiative – rising to about 9 million in 2009. A carbon reduction program focused on logistics has been embedded into 2010 corporate objectives. And our travel booking tool allows employees to see the carbon footprint of their business trips. With an active travel policy control, we were able to reduce overall business travel by 20% in 2009. For many years our production facilities have focused on reducing their consumption of energy, water and hazardous materials.

Eco-friendly products

Gemalto has a long-standing portfolio of eco-friendly products for banking, telecom and government customers worldwide. This was recently expanded, further reducing environmental impact in three key areas:

Reducing hazardous substances

Gemalto actively seeks ways to reduce the use and disposal of hazardous substances during production, e.g.:

  • In our advanced Card Center in Pennsylvania, US, we succeeded in eliminating ink jets by replacing them with laser inscription.
  • We are treating and recycling rags which were previously discarded in the process of cleaning manufacturing equipment.
  • We are increasing the use of vegetable-based inks in the printing process.

Using chlorine-free materials

In 1997 Gemalto began to move to non-chlorine polymers resulting in the majority of our current products being chlorine free. These include:

  • PETG(*) based products: a chlorine-free alternative to PVC, PETG can be incinerated without creating harmful gases or air pollution.
  • ABS molded cards: these are PVC free and significantly reduce the amount of waste during production.
  • PC Twin Reader: the first smart card reader which satisfies eco-design criteria, anticipates legal requirements on hazardous substances and is easier to recycle.
  • Small form factor cards: which reduce the amount of material required in production.
(*)
Polyethylene Terephthalate Glycol.

Promoting renewable and recycled materials

Gemalto actively promotes renewable and recycled materials, reducing the overall environmental footprint of our production processes, e.g.:

  • Polylactic Acid (PLA) card: a new bio-sourced material which is easily recyclable and compostable.
  • Paper-based materials for short-term use, such as scratch cards.
  • ECOPack: eco-friendly packaging made of 100% recyclable materials for our fulfillment services.
  • Recycling production waste to make boat masts.