How Alcoa Canned the Cost of Recycling

Alcoa is one of the world?s largest aluminium smelting and casting multinationals, and involves itself in everything from tin cans, to jet engines to single-forged hulls for combat vehicles. Energy costs represent 26% of the company?s total refining costs, while electricity contributes 27% of primary production outlays. Its Barberton Ohio plant shaved 30% off both energy use and energy cost, after a capital outlay of just $21 million, which for it, is a drop in the bucket.

Aluminium smelting is so expensive that some critics describe the product as ?solid electricity?. In simple terms, the method used is electrolysis whereby current passes through the raw material in order to decompose it into its component chemicals. The cryolite electrolyte heats up to 1,000 degrees C (1,832 degrees F) and converts the aluminium ions into molten metal. This sinks to the bottom of the vat and is collected through a drain. Then they cast it into crude billets plugs, which when cooled can be re-smelted and turned into useful products.

The Alcoa Barberton factory manufactures cast aluminium wheels across approximately 50,000 square feet (4,645 square meters) of plant. It had been sending its scrap to a sister company 800 miles away; who processed it into aluminium billets – before sending them back for Barberton to turn into even more wheels. By building its own recycling plant 60 miles away that was 30% more efficient, the plant halved its energy costs: 50% of this was through process engineering, while the balance came from transportation.

The transport saving followed naturally. The recycling savings came from a state-of-the-art plant that slashed energy costs and reduced greenhouse gas emissions. Interestingly enough, processing recycled aluminium uses just 5% of energy needed to process virgin bauxite ore. Finally, aluminium wheels are 45% lighter than steel, resulting in an energy saving for Alcoa Barberton?s customers too.

The changes helped raise employee awareness of the need to innovate in smaller things too, like scheduling production to increase energy efficiency and making sure to gather every ounce of scrap. The strategic change created 30 new positions and helped secure 350 existing jobs.

The direction that Barberton took in terms of scrap metal recycling was as simple as it was effective. The decision process was equally straightforward. First, measure your energy consumption at each part of the process, then define the alternatives, forecast the benefits, confirm and implement. Of course, you also need to be able to visualise what becomes possible when you break with tradition.

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Why integrating your Field Service Management with IoT Applications makes sense

Your customers want a smooth experience when hiring your services. Whether there are pests that have run amok in their homes and you have been called in to exterminate them, there is a leak in the pipes and your plumbing repair business is the go-to for repairs, you’re in charge of a cleaning business with clients spanning across the residential and commercial niches, or even a locksmith making new installations and providing aftercare for their clients ? it is vital to make the process as hassle-free as possible for your customer. The priority is getting the job done in time, and to quality standards. On the other hand, your mobile workers need access to complete and accurate data to approach the task more proactively, get it done right, and increase the rate of first-time fixes.

When you have multiple clients and a huge workforce, things can get messy with all the paperwork involved. Preparing documents and reports, keying in the data, keeping track of your mobile employees, following up on current jobs and scheduling new appointments ? the workload can put a strain on your staff. Field service scheduling software like FieldElite come in to keep your central office staff abreast with all customer details, sending alerts when new issues arise. These are then relayed to the appropriate technician for the situation to be taken care of at the earliest possible time ? directing the right employee to the customer based on the skill-set availability and location. While field service job management software, by itself, is a powerful solution, you can crank things up a notch by having a system that integrates IoT into its operations.

Powering Field Service Scheduling Software Systems With IoT

FSM gives maintenance firms, distributors, manufacturers and other service businesses an interactive platform that optimises the workflow. From the customers booking maintenance work, office staff tracking operations right from their desk, workers interacting with it while on-ground through the mobile app, to the billing and invoicing ? it is all handled through the same system. IoT applications can boost this becoming a critical tool to show the field managers about the precise locations where attention is needed, for accurate worker and job scheduling and improved customer satisfaction. What if you could also have features like auto-scheduling coming on board? Let’s delve deeper into what it means for your FSM system.

Benefits Of Using Service Management Software With IoT Solutions

Its impact of IoT on field management is seen in the transformation of maintenance data into proactive service actions. Research by Gartner shows that in 2020 there will be over 20 billion connected devices, making the reach of IoT really vast. This will fuel the field management industry, unlocking more potential with the mobile workers interacting in real-time with their equipment and headquarters. This speeds up response time to service requests and transforms interoperability across the different devices.

???????? All-round access

The interaction with IoT benefits the technicians, managers, and customers themselves. For instance, while the worker on ground interacts with the FieldElite mobile app, the office staff at headquarters will be engaging them via browser on their smart devices, and even the client gets access to the system through the customer portal.

???????? Linking your different business operations

It doesn’t stop there. Integrating the mobile service management software to the IoT facilitates inventory management, automobile tracking, and even automates accounting, invoicing, and other internal processes of the business, giving you more visibility over your field assets and operations. Here, the sensors that have been enabled in the network will notify you of damaged equipment, and go further to route and dispatch the technician who is most suited to go on-site and repair it.

???????? Nip things in the bud ? A proactive approach

Updates from sensors on the remote equipment are sent over a dedicated network. This is intelligently interpreted by the IoT platform to decide the next course of action, depending on a predefined set of rules. This course of action can be assigning and dispatching the technician through the FieldElite app to fix the equipment before permanent damage occurs. This whole process is automatic, shifting the company from a reactive mode of operations to a proactive and preventative model, resulting in better utilisation of assets.

???????? Minimise time wastage

Less time is spent going checking for flaws in the systems. Take management at a wastewater treatment plant for instance. Simply place IoT sensors on the different pumps, mortars and valves to give you this data. In case of leaks or damage, the appropriate operator is alerted, taking away the need for manual monitoring. Monitoring is done remotely. Hazardous situations such as in the oil and gas industry where workers are faced with issues like flare stacks are handled better, where the IoT sensors minimise downtime and ensure that only necessary visits to the plat equipment are done.

???????? Interactions at the palm of your hand

The field service workers are also equipped with effective communications through aspects like the chat feature on the mobile app, and reporting abilities where they can make notes, take photos and relay this to the headquarters during the course of the job. Information on the system is readily available to the customer and future technicians who will be handling jobs at the facility.

How does the FSM work with other systems? FieldElite’s core role is to manage the mobile workforce. How do you keep track of the sensors of the different equipment, in order to know when maintenance is needed?

Enter ecoVaro: IoT In Energy Management

The 2018-2025 Global Building Energy Management System Analysis and Forecast showed energy consumption in residential buildings accounts for close to 40% of the world’s energy consumption.? Commercial buildings like shopping malls, hospitals, retail stores and hotels take 30%. IoT tools aid in collecting and analysing the real-time data consumption in these falsities, to improve maintenance and reduce down times. It’s a holistic view that is achieved through a network of smart devices monitoring the ventilation, humidity, air-conditioning and lighting systems.

Home automation tools like smart thermostats and bulbs are already becoming popular. Here, they bring savings to the consumers without them having to use up much effort. For broader energy management, these systems will include units like sensors, controls, meters, data analytics tools, and user-friendly applications that the consumers access all this from. It cuts across the board, from households and commercial establishments, to utility firms and government bodies keen on effectively monitoring and managing their energy resources. Industrial and commercial users need data analytics tools to maximise their productivity and reduce costs, while residents in households want to reduce their monthly bills and take a more proactive role in their energy management.

From Smart Devices To Accurate Loggers

The first step in saving energy is cutting down wastage. Smart light, humidity, temperature and air conditioning controls come in to maintain optimal indoor conditions. Lighting units, smart thermostats, sensor-based HVAC control systems are part of the IoT, taking centre stage in automatically maintaining the perfect indoor environment that will keep the building?s energy use at optimum levels. They have been designed with different sensors that check the humidity, light, motion and even CO2 levels, dynamically adjusting the conditions in the facility. Here, you have situations like smart lights dimming when there is more daylight getting into the room, and then automatically turning off when people leave the room. The smart thermostats can precool the indoor space before the day gets warmer, so that during that scorching midday sun there will be less energy spent by the HVCA to bring down the heat levels.

The whole set up ? from the LED lights adjusting to user preferences and routines, learning thermostats that reduce consumption during peak load times, sensors and data analytics that give the user more control over their consumption, creates a smart energy infrastructure, be it in homes or industrial spaces, from retail stores and factories, to entire cities. This is all geared at cutting down energy costs, with the systems automatically adjusting the building?s lighting, temperature and ventilation, to reduce the energy consumption without compromising the comfort of the building?s occupants. LEED bulbs already record 20% lower maintenance costs than the typical commercial buildings.

Adopting IoT Applications For Your EMS System

How can you take advantage of this? With the EMS loggers, you monitor your facility’s consummation in real-time. Platforms like ecoVaro enable both the utility companies and end-users to access this data. The utility firms will be in a position to tailor the power supply in response to changing demand and also adjust their pricing. The end-users, on the other hand, will be in a position to control their usage at a granular level ? responding to changing environmental conditions, power consumption, and reducing energy waste.

There are also those appliances that come with sensors, from boilers in the household, to heavy production machinery in industries. The EMS systems allow you to continuously monitor the load on the sensor-enabled assets, predict when overheating will occur and pinpoint risks of outages or damage on the line. Maintenance can then be immediately carried out to vent damages to the equipment. That way components like motors are protected from damages that would have ended up costing the firm lots of funds to replace. The data analytics from the EMS platforms enable the energy manager to strike that balance to optimise performance and reduce wear, thus prolonging the life of the equipment.

Even the heavy hitters in the energy sector get to benefit from the IoT. Take power production for instance. When you’re dealing with stations, solar farms and wind fields ? as they provide that much-needed power, they also consume energy and need plenty of maintenance. These are resource-heavy stations and as a manager, you want to keep a close eye on things. This involves a complex approach, from the sensors at the facilities, data analytics, to predictive maintenance. EMS software comes in to continuously monitor the equipment and wiring through the sensors. This enables you to prevent issues like overloads, and ensure that a balanced load is maintained on the line. The EMS goes a step further by enabling you to undertake predictive maintenance, for the timely repair of the equipment on the power grid, minimising accidents, preventing blackouts, and averting the costly down times.

Electricity utilities connecting their power plants and grids to available IoT solution networks get to be more transparent to their consumers, by showing them where the energy they use comes from. This empowers the consumers with the information needed to select the cleanest energy source during that period, which is particularly beneficial for those keen on adopting greener practices. For instance, you can have a system monitoring a network of grids, and dynamically shifting to power sources that have the least amount of emissions at the moment ? what’s gaining popularity as “automated emission reduction”. These lead to utility firms that produce clean energy getting more consumers and growing their revenue base.

Field And Energy Management: How FieldElite and ecoVaro Work Together Through IoT

So, on one hand, you have the energy managers following up on the consumption trends at their facilities, keeping an eye on their equipment.? On the other hand, you have field workers needed to carry out repair and maintenance works at different locations.? How do you join them together to ensure a seamless flow of operations?? The IoT.

This can be seen with ecoVaro and Field Elite interaction. Here, you have two independent systems that are interlinked through the internet and secure cloud systems, bringing more convenience on board for the users.

Picture this: Loggers collecting data from the meters and sensors on-site detect an anomaly, which you will immediately be able to view through the ecoVaro platform. This can be a myriad of issues, from plumbing to electrical systems that need to be worked on, and they are at multiple locations. How do you get them resolved? Dispatch your technicians through FieldElite.

Here’s a snapshot of how this works:

FieldElite and Ecovaro Working Together

This way, you get to optimise your operations and cut down on coasts ? taking advantage of the data analytics tools brought to you by ecoVaro, and streamlining your workflow through FieldElite. IoT powered workforce and energy management systems thus become key in reducing operational expenses, scheduling repairs and maintenance, and planning for peak hours

Accessing real-time data has the welcome benefit of cutting down on the hours spent on energy management processes. Jobs like meter reading that would have taken lots of time are handled by the system. When it comes to field management, operational efficiency is increased by taking away the manual processes involved with all the paperwork.? The sensors monitored via ecoVaro alert the field service manager about equipment that needs to be checked, and FieldElite shows the field manager issues that are on queue to be resolved. In both cases, you get accurate data that will inform the decisions made ? from the maintenance measures required, to scheduling the jobs for the technicians to handle them. It’s a win-win situation.?

Building Blocks For A Brighter Tomorrow

What’s more, this sets you up for the future. Adopting IoT solutions for your field and energy management operations will score you higher ROIs going forward. The global community is working towards enhancing the efficiency of its operations and putting in place sustainable practices in line with their Social Corporate Responsibility (CSR). This is from service providers like plumbing and electrical repair businesses, to utility firms and power generation plants. Lighting systems, homes, office buildings, factories, communities, transportation and whole cites are getting connected through the internet and more control done via smart devices. This is further accelerated by cloud systems enabling real-time, reliable and secure access to the information. By incorporating these setups into your business structure, you will gain a competitive advantage in your niche. After all, we’re still in the early stages of IoT across the industries.

Technology and process improvement

Tightening organisational flow to improve productivity and minimise costs is a growing concern for many businesses post the Global Financial Crisis. Businesses can no longer afford to waste time and personnel on inefficient processes. Organisations using either Six Sigma or Lean techniques better manage their existing resources to maximise product out-put. Both of these techniques involve considerable evaluation of current processes.

What is Six Sigma?

Six Sigma is an organisational management strategy that evaluates processes for variation. In the Six Sigma model, variation equates waste. Eliminating variation for customer fulfilment allows a business to better serve the end-user. In this thought model, the only way to streamline processes is to use statistical data. Each part of a process must be carefully recorded and analysed for variation and potential improvements. The heart of the strategy embodied by Six Sigma is mathematical. Every process is subject to mathematical analysis and this allows for the most effective problem solving.

What is a Lean Model?

Lean businesses do not rely on mathematical models for improvement. Instead, the focus is on reducing steps in the customer delivery cycle, which do not add value to the final deliverable. For example, maintaining excess inventory or dealing with shortages would both be examples of waste behaviour. Businesses that operate using Lean strategies have strong cash flow cycles. One of the best and most famous examples of Lean in action is the Toyota Production System (TPS). In this system, not only is inventory minimised, but physical movement for employees also remains sharply controlled. Employees are able to reach everything needed to accomplish their tasks, without leaving the immediate area. By reducing the amount of movement needed to work, companies also remove wasted employee time.

Industry Applications for Lean and Six Sigma

Lean businesses reduce the number of steps between order and delivery. The less inventory on hand, the less it costs a business to operate. In industries where it is possible to create to order, Lean thinking offers significant advantages. Lean is best utilised in mature businesses. New companies, operating on a youthful model, may not be able to identify wasteful processes. Six Sigma has shown its value across industries through several evolution’s. Its focus on quality of process makes it a good choice for even brand new businesses. The best use is the combination of the two strategies. With the Lean focus on speed and the Six Sigma focus on quality combined, the two organisational processes create synergy. By itself, Lean does not help create stable, repeating success. Six Sigma does not help increase speed and reduce non value-added behaviours. Combined, these two strategies offer incredible value to every business in cost savings.

Using Technology to Implement Lean Six Sigma

Automation processes represent an opportunity for businesses to implement a combination of both Lean and Six Sigma strategies. Any technology that replaces the need for direct human oversight reduces costs and increases productivity. A few examples of potentially cost saving IT solutions include document scanning, the Internet, and automated workflow systems.

  • Document Scanning – Reducing dependency on paper copies follows both Lean and Six Sigma strategies. It is a Lean addition in that it allows employees to access documents instantly from any physical location. It is Six Sigma compliant in that it allows a reduction on process variation, since there is no bottleneck on the flow of information.
  • The Internet – The automation potential offered by the Internet is limitless. Now, businesses can enter orders, manage logistics and perform customer service activities from anywhere, through a hosted portal. With instant access to corporate processes from anywhere, businesses can manage workflow globally, allowing them to realise cost savings from decentralisation.
  • Automated Work Systems – One of the identified areas of waste in any business is processing time. The faster orders are processed and delivered, the greater the profits for the company and the less the expense per order. When orders sit waiting for attention, they represent lost productivity and waste. Automated work systems monitor workflow and alert users when an item sits longer than normal. These systems can also reroute work to an available employee when the original worker is tied up.

Each of these IT solutions provides a method for businesses to either reduce the number of steps in a process or improve the quality of the process for improved customer service.

Identifying Areas for Lean Six Sigma Implementation

Knowing that improved processes result in improved profits, identifying areas for improvement is the next step. There are several techniques for creating tighter processes with less waste and higher quality. Value Stream Mapping helps business owners and managers identify areas of waste by providing a visual representation of the total process stream. Instead of improving single areas for minimal increases in productivity, VSM shows the entire business structure and flow, allowing management to target each area of slow down for maximum improvement in all areas.

Seeing the areas of waste helps management better determine how processes should work to best obtain the desired outcomes. Adding in automated processes helps with improved process management, when put in place with a complete understanding of current systems and their weaknesses. Start with mapping and gain a bird’s-eye view of the situation, in order to make the changes needed for improvement.

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Mobile Workforce Management in a nutshell

It is fairly common for businesses to have staff working across many different locations across the country or even the world.  Engaged in various activities like  door-to-door sales, delivery and installations, service maintenance, conducting inspections & investigations or even data collection.

Managing and co-ordinating tasks, scheduling activities, planning and monitoring activities and communicating can often be challenging.

Mobile Workforce Management is the automation of the entire end-to-end workflow management and operations of any field service workers. 

Mobile Workforce Management Synonyms

Mobile Workforce Management is also known as

  • Field Service Management
  • Job Scheduling Software
  • Job Management Software

Advantages of Mobile Workforce Management

It is increasingly clear that there needs to be a certain sense of discipline and streamlining of field operations and important to automate certain tasks within field sales and operations, primarily because it helps you to track your assets remotely and ensuring contact with your workforce when required. Enabling your team to get in touch when required.

Most importantly, engineers, sales representatives and customer care executives can easily send information, scan receipts, Invoice customers and retrieve other crucial information in a standardized and streamlined manner. Assisting in regulating your business and also bringing some order to what is usually a very chaotic mode of working.

Why choose Mobile Workforce Management

Work Force Management tools help you to stay in control. They assist in automating what can and should be automated leaving only the crucial human-human interactivity. Helping you to keep a record of all interactions and important data within a database, without you having to manually go through sales receipts, complaint slips and other such details.

A Field Force Management tool is a time-saver and efficiency tool for companies. Moreover, these tools help to automate several aspects of your day to day operations, leading to an increase in productivity and motivation.

Streamlining operations, will also ensure that important stakeholders are well informed and management visibility is enhanced. Helping your business to make smarter decisions and help serve your customers better.

Field Force Management is similar to an Enterprise Resource Planning (ERP) solution but is vastly different. It is specifically targeted at staff that work on the field and is intended to make their and your work more streamlined, transparent and easy to track.

Cloud based solutions help you automate

 Field Force Management is usually cloud based which means all data is stored and accessible on secure cloud servers. There is no question of losing important data or not being able to retrieve something important. If something goes missing, there will usually be a backup available. Field force management tools include the software, the hardware and also the kind of training that is required for users to use it efficiently.

The software usually helps in saving and processing information while the hardware helps employees to enter important data into devices while they are on the job. Sometimes, field force solutions can also be a mobile app which negates the need for a specific or special device.

This is very important when it comes to field jobs as carrying different devices can prove to be a cumbersome job. At the end of the day, field force solutions are meant to reduce the burden on staff and not actually inadvertently increase it.

Denizon?s FieldElite Mobile Workforce management application provides significant improvements in efficiency and service with a switch to digital working and the elimination of paperwork.

All the information that is stored on the cloud can be run through analytics software so that you get the kind of reports that you are looking for to improve your business.

Field Force Management Process

A field force management tool helps you to remain in contact with your staff while they are at work on the field. This helps you to track your personnel in real time. Field personnel or your staff can log in and enter their attendance using a smartphone. You can assign that particular day?s task remotely using a web console or your own smartphone.

Next, they can carry out whatever duties they need to while you get all the alerts that you set to receive. This helps to increase transparency. You can choose to receive alerts on your phone or on your desktop.

Finally, staff can tag completed tasks with audio and images, instead of they having to type reports. This helps to focus more on the job than on job reporting. Last but not the least, location tags help you to ensure that the job is done at the right place. Your staff will not be able to take your generosity for granted.

All in all, a field force management tool helps you to track and control your staff without you having to be physically present with them and this is the beauty of this tool.

Summary

Field Force Management helps companies to reduce administration expense and improve productivity. This helps to automate data integration which is usually done with the help of cloud servers. Moreover, you can set invoice parameters that help you to also keep track of stocks, inventories and engage in P.O. and task management.

A number of field force management users also use it as a tool to engage in credit management. Banks and insurance companies particularly find this tool helpful as payments can be received on the job, instead of asking customers to pay online or offline. This also helps in building valuable customer relationships and enhance loyalty.

Thirdly, a field force management tool helps to increase planning efficiency. This means, you will be able to allocate tasks and optimize routing. All this helps to increase your ROI at the end of the day and get back the money you invest on field force management.

Finally, you will have more control over productivity and sales thanks to automation of data collection. You will also have more control over the execution of tasks and that will invariably make your company leaner and smarter.

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