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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Sources of Carbon Emissions

Exchange of carbon dioxide among the atmosphere, land surface and oceans is performed by humans, animals, plants and even microorganisms. With this, they are the ones responsible for both producing and absorbing carbon in the environment. Nature?s cycle of CO2 emission and removal was once balanced, however, the Industrial Revolution began and the carbon cycle started to go wrong. The fact is that human activities substantially contributed to the addition of CO2 in the atmosphere.

According to statistics gathered by the Department of Energy and Climate Change, carbon dioxide comprises 82% of UK?s greenhouse gas emissions in 2012. This makes carbon dioxide the main greenhouse gas contributing to the pollution and subsequent climate change in UK.

Types of Carbon Emissions

There are two types of carbon emissions ? direct and indirect. It is easier to measure the direct emissions of carbon dioxide, which includes the electricity and gas people use in their homes, the petrol burned in cars, distance of flights taken and other carbon emissions people are personally responsible for. Various tools are already available to measure direct emissions each day.

Indirect emissions, on the other hand, include the processes involved in manufacturing food and products and transporting them to users? doors. It is a bit difficult to accurately measure the amount of indirect emission.

Sources of Carbon Emissions

The sources of carbon emissions refer to the sectors of end-users that directly emit them. They include the energy, transport, business, residential, agriculture, waste management, industrial processes and public sectors. Let’s learn how these sources contribute carbon emissions to the environment.

Energy Supply

The power stations that burn coal, oil or gas to generate electricity hold the largest portion of the total carbon emissions. The carbon dioxide is emitted from boilers at the bottom of the chimney. The electricity, produced from the fossil fuel combustion, emits carbon as it is supplied to homes, commercial establishments and other energy users.

Transport

The second largest carbon-emitting source is the transport sector. This results from the fuels burned in diesel and petrol to propel cars, railways, shipping vehicles, aircraft support vehicles and aviation, transporting people and products from one place to another. The longer the distance travelled, the more fuel is used and the more carbon is emitted.

Business

This comprises carbon emissions from combustion in the industrial and commercial sectors, off-road machinery, air conditioning and refrigeration.

Residential

Heating houses and using electricity in the house, produce carbon dioxide. The same holds true to cooking and using garden machinery at home.

Agriculture

The agricultural sector also produces carbon dioxide from soils, livestock, immovable combustion sources and other machinery associated with agricultural activities.

Waste Management

Disposing of wastes to landfill sites, burning them and treating waste water also emit carbon dioxide and contributes to global warming.

Industrial Processes

The factories that manufacture and process products and food also release CO2 , especially those factories that manufacture steel and iron.

Public

Public sector buildings that generate power from fuel combustion also add to the list of carbon emission sources, from heating to other public energy needs.

Everybody needs energy and people burn fossil fuels to create it. Knowing how our energy use affects the environment, as a whole, enables us to take a step ahead towards achieving better climate.

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Large scale corporate transformation

Large scale corporate transformation are the necessary actions required to increase performance in an organisation. It leads to greater performance results and greater organisational growth. It is a lasting change and can range from getting new leaders to combining the functions of different departments. It can also involve the introduction of a new phase in the life of an organisation. Large scale corporate transformation can be measured using three variables. The first variable involves determining how deep the change penetrates to all levels of the organisation. The second variable measures how entrenched it becomes in the organisation while the third measure determines the percentage of the organisation covered in the change.

Corporate transformation is essential for a company that seeks to have a greater impact and a longer life in its business sector. The process requires time and resources. The whole establishment needs to support it for success. Not only does the top management need to back it, but stockholders and staff members also need to buy the idea. This is because when the process of corporate transformation hits a barrier, it will take the entire organisation to keep it on course and complete the process. Without the support of everyone, most organisations will not complete the process.

Business transformation in recent times has begun to combine finance, HR and IT departments into one functioning piece of an organisation. This has resulted in leaner, faster, and more efficient corporate entities that produce high results and has a greater impact in its overall functioning. These three key departments are the backbone of any organisation, and the combination of the three creates an efficient organisation that translates into high performance results.

One crucial aspect of large scale corporate transformation is IT transformation, which entails the entire overhaul of any organisation’s technology systems. It adopts a more efficient platform that enhances its overall operation. IT transformation involves the use of Service Oriented Architecture (SOA) and open systems. This process is the revamping of the existing technology used to support the organisation and is critical for aligning the business functions to the mission of the organization. It touches on the current hardware and software and how they can best be improved upon for greater results. This process is necessary in the entire business transformation.

The question that needs to be addressed is how any organisation can make this process successful. First, it requires the understanding that it is not just a goal to be achieved, but a new way of thinking embraced by the entire organisation. Secondly, the leadership in place needs to be fully involved and dedicated to the process and to realise that it takes time and effort to complete such a mission. There also needs to be flexibility and adaptability in order to learn from mistakes and keep moving forward. Constant communication is also critical to ensure that everyone involved understands the current stage and the next steps to be done. Change is the only constant and is necessary for progress and success.

Increase Customer Loyalty with Field Service Management Software

One sure way to turn off customers is to give them a disappointing experience. It cuts across the board- from plumbing jobs, electrical installation and maintenance projects, window cleaning or repair, tenants in the property you’re managing, to package delivery firms. If your customers keep witnessing delays, cancelled appointments, to oversights like double booking which end up messing their individual schedules, they are likely to stop hiring your services and seek out a competitor.?

Field service jobs are particularly prone to such blunders, especially with the traditional manual way of doing things. While smartphones and computers have been infused into the day-to-day running of businesses, it is still common to find companies relying on manual processes to schedule their appointments, track the employees providing the services, monitor the progress of the jobs and ask for status updates, to managing inventory and invoices for completed tasks. This creates a major bottleneck in operations. The Small & Medium Business Trends Report, that took responses from nearly 500 SMB owners and leaders, showed that they spend an average of 23% of each workday manually inputting data. This is time that would have otherwise been spent tending to the customers? needs. It creates a backlog of tasks, forcing the customers to wait for longer to get their issues handled.?

The inefficiencies witnessed in these traditional methods led to the advent of field service business management software. These systems come in to optimise operations and enhance your service delivery. As a business, automating your scheduling, job tracking, routing procedures and handling the invoicing, all through a single platform, greatly reduces your workload. Managing inventory, communicating with your employees out in the field through handy apps on their phone, giving them access to a database of reports and notes on the various jobs they have been tasked with – these all aid in smoothing out the sorting of tasks, and gets rid of the mounds of paperwork that would have been required.?

From Your Customer’s Perspective

When you’re facing a plumbing leak at home, electrical faults that result in power outages in the office building, damaged gas boilers that are hampering operations in the industrial plants- you want them to be addressed. Homeowners, business owners and facility managers in these situations are anxious about getting the issue resolved- yet the firm they are relying on to handle it is caught up in a logistical nightmare, boggled down by paperwork that prevents them from sending their technicians to the location. You really don’t want to hear a series of excuses about why your problem could not be addressed in time. While delays can be a nuisance, cancelled appointments are altogether exasperating. See, the customer is left in a difficult position, since the problem is not resolved, and they have to contend with having to make a subsequent appointment- of which they will not be sure if they can bank on the hired firm to deliver on its mandate. With an FSM, you get to prevent such incidents from occurring.

How Your Customers Benefit From Field Service Job Management Software

Reliable services

Firstly, the customer wants services that they can count on. When an issue arises and an appointment scheduled, they want it to be honoured. With the FSM, you get to accurately schedule the tasks, from the timing involved to assigning it to the appropriate technician, who is skilled in the task. With the automated scheduling and dispatching, the technician downtime that was previously witnessed is reduced- which has the welcome benefit of cutting down your operational costs.?

Speaking of which, the confusion that was previously seen when perusing through documents and simply calling up the first employee whose skill is similar to the job description, is avoided. Here, the field service management platform enables you to determine the most appropriate member of your workforce to handle the task. This makes them more motivated at their job, resulting in higher quality results- whether it’s an installation task, repair and maintenance project, or cleaning service for companies providing them in residential and commercial buildings.?

Get it done right the first time around

The field service scheduling software enables the technician to have all the information pertaining to the job accessible in real-time. This is availed via app– that the technicians will have on their phones. It is through this very app that they will make updates of the tasks being handled, sending in notes, photos and reports to the system. These will, in turn, be monitored at the head office all through the progress of the job, being managed through the interactive FSM dashboard.?

With the customer’s history being accessed by the technician, information that includes the specs and hazards about the particular job being handled, notes from the previous technicians who had been tasked to the building- such as the installation crew and previous repairs that had been done, will enable the personnel on the ground make well-informed decisions throughout the course of the task. Any issues that arise will also be taken note of, equipment and parts ordered through the app as well, ensuring that things proceed seamlessly. That way, the percentage of situations getting fully resolved during the first appointment increases- which translates to fewer cases of complaints being made.?

Instant invoicing

Immediately the job is done, the customer inputs their e-signature through the app, and the technician marks the task as completed, the very same FSM is used to process the invoice and send out an emailed copy to the customer. This will be an accurate invoice, without any data loss, and the customer can then proceed to make the payment through their preferred mode- from credit card payments to cash, without having to wait for hours for paperwork to be processed. All this information is securely stored on the cloud-based platform.

Creating a great first impression

Your image is a core part of your operations. Certainly, you don’t want to come off as disorganised- and your customers will be quick to note this with issues like missing records, outdated reports, lateness, and improper assigning of tasks. On the other hand, having a modern digital solution integrated into your field service operations will enable you to make a great first impression, showing the level of professionalism with which you offer your services.

Customer access

FSM platforms like FieldElite also give the customers themselves access to the system, through their own dashboard. This is particularly handy given that there are cases where the customer will have multiple jobs to be carried out- like property managers who keep on having cases of plumbing accidents, electrical faults, and cleaning service needs in the different buildings that they are in charge of.?

Through the customer portal, they will be able to make appointments, track the history of repair and maintenance jobs carried out on the property, and follow up on queries. What’s more, together with the IoT where FieldElite links to ecoVaro, one can have an interactive energy management system in place to keep accurate tabs on the energy consumption, efficiency, point out areas where repairs are needed, and have technicians come over- with the bookings being made through the FSM.

Enhance Customer Experience And Score New Business Opportunities

Customer service is a key aspect of your operations. When your customers are well tended to, with their needs being met in a timely and proficient manner, it wins you their loyalty, and they’ll be more open to sending referrals your way- growing your market share. Feedback- from testimonials on your site to the reviews on your social media handles, also aids in this- and you want to have satisfied clients who will put out a good word about your brand. By investing in field software for service businesses, you will increase your employees? productivity, monitor trends, improve communication between your head office and the technicians on the ground, all of which come together to increase customer satisfaction.

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