What Energy Management Software did for CDC

Chrome Deposit Corporation ? that’s CDC for short ? reconditions giant rollers used to finish steel and aluminium sheets in Portage, Indiana by applying grinding, texturing and plating methods. While management was initially surprised when the University of Delaware singled their plant out for energy assessment, this took them on a journey to bring energy consumption down despite being in an expansion phase.

Metal finishing and refinishing is an energy-intensive business where machines mainly do the work while workforces as small as 50 individuals tend them. Environmental impacts also need countering within a challenging environment of burgeoning natural gas and electricity prices.

The Consultant’s Recommendations

The University of Delaware was fortunate that Chrome Deposit Corporation had consistently measured its energy consumption since inception in 1986. This enabled it to pinpoint six strategies as having potential for technological and process improvements.

  • Insulate condensate tanks and pipes
  • Analyse flue gas air-fuel ratios
  • Lower compressed air pressures
  • Install stack dampers on boilers
  • Replace belts with pulleys and cogs
  • Fit covers on plant exhaust fans

CDC implemented only four of the six recommendations. This was because the boiler manufacturer did not recommend stack dampers, and the company was unable to afford certain process automation and controls.

Natural Gas Savings

The project team began by analysing stack gases from boilers used to heat chrome tanks and evaporate wastewater. They found the boilers were burning rich and that several joints in gas lines were leaking. Correcting these issues achieved an instant gas saving of 12% despite increased production.

Reduced Water Consumption

The team established that city water was used to cool the rectifiers. It reduced this by an astonishing 85% by implementing a closed-loop system and adding two chillers. This also helped the water company spend less on chemicals, and energy to drive pumps, purifiers and fans.

Summary of Benefits

Electricity consumption reduced by 18% in real terms, and natural gas by 35%. When these two savings are merged they represent an overall 25% energy saving. These benefits were implemented across the company?s six other plants, resulting in benefits CDC management never dreamed of when the University of Delaware approached them.

ecoVaro offers a similar data analytics service that is available online worldwide. We have helped other companies slash their energy bills with similarly exciting results. We?ll be delighted to share ideas that only data analytics can reveal.

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Transformation to a process based organisation

Today’s global marketplace rewards nimble organisations that learn and reinvent themselves faster than their competition. Employees at all levels of these organisations see themselves as members of teams responsible for specific business processes, with performance measures tied to the success of the enterprise. As team members, they are “owners” of the process (or processes) to which they are assigned. They are responsible for both the day to day functioning of their process(s), and also for continuously seeking sustainable process improvements.

Transforming a traditionally designed “top down control” enterprise to a process-based organisation built around empowered teams actively engaged in business process re-engineering (BPR) has proven more difficult than many corporate leaders have expected. Poorly planned transformation efforts have resulted in both serious impacts to the bottom line, and even more serious damage to the organisation’s fabric of trust and confidence in leadership.

Tomislav Hernaus, in a publication titled “Generic Process Transformation Model: Transition to Process-based Organisation” has presented an overview of existing approaches to organisational transformation. From the sources reviewed, Heraus has synthesised a set of steps that collectively represent a framework for planning a successful organisational change effort. Key elements identified by Hernaus include:

Strategic Analysis:

The essential first step in any transformation effort must be development of a clear and practical vision of a future organisation that will be able to profitably compete under anticipated market conditions. That vision must be expected to flex and adjust as understanding of future market conditions change, but it must always be stated in terms that all organisational members can understand.

Identifying Core Business Processes:

With the strategic vision for the organisation in mind, the next step is to define the core business processes necessary for the future organisation to function. These processes may exist across the legacy organisation’s organisational structures.

Designing around Core Processes:

The next step is development of a schematic representation of the “end state” company, organised around the Core Business Processes defined in the previous step.

Transitional Organisational Forms/ Developing Support Systems:

In his transformation model, Hernaus recognises that information management systems designed for the legacy organisation may not be able to meet the needs of the process management teams in the new organisation. Interim management structures (that can function with currently available IT system outputs) may be required to allow IT professionals time to redesign the organisation’s information management system to be flexible enough to meet changing team needs.

Creating Awareness, Understanding, and Acceptance of the Process-based Organisation:

Starting immediately after the completion of the Strategic Analysis process described above, management must devote sufficient resources to assure that all organisation members, especially key managers, have a full understanding of how a process-based organisation functions. In addition, data based process management skills need to be provided to future process team members. It is not enough to schedule communication and training activities, and check them off the list as they are completed. It is critical that management set behavioural criteria for communication and training efforts that allow objective evaluation of the results of these efforts. Management must commit to continuing essential communication and training efforts until success criteria are achieved. During this effort, it may be determined that some members of the organisation are unlikely to ever accept the new roles they will be required to assume in a process-based organization. Replacement of these individuals should be seen as both an organisational necessity and a kindness to the employees affected.

Implementation of Process Teams:

After the completion of required training AND the completion of required IT system changes, process teams can be formally rolled out in a planned sequence. Providing new teams with part time support by qualified facilitators during the firsts weeks after start-up can pay valuable long term dividends.

Team Skill Development and Continuous Process Improvement:

Providing resources for on-going skill development and for providing timely and meaningful recognition of process team successes are two keys for success in a process-based organisation. Qualified individuals with responsibility for providing training and recognition must be clearly identified and provided with sufficient budgetary resources.

The Hernaus model for transformation to a process based organisation is both well thought out and clear. His paper provides an ample resource of references for further study.

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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.

What ISO 14001 Status did for Cummins Inc.

Cummins manufactures engines and power generation products, and has been a household name almost since inception in 1919. It sells its products in over 300 countries, through approximately 6,000 dealerships employing 40,000 people. Because its product line runs off fossil fuel it is under steady pressure to display a cleaner carbon footprint.

Cummins decided to go for the big one by qualifying for ISO 14001 certification. This is a subset of a family of standards relating to managing environmental impact while complying with all applicable legislation. In this sense, it is similar to the ISO 9000 quality management system, because it focuses on how products are produced (as opposed to how those products perform). Compliance with ISO 14001 was a doubly important goal, because it is part of the European Union?s Eco Management and Audit Scheme and fast becoming mandatory on suppliers to governments.

The qualification process follows the well-established principle of plan, do, check, act. It begins with gap analysis to detect materials and processes that affect the environment. This is followed by implementation of necessary changes affecting operations, documentation, emergency strategies and employee education. The third step involves measuring and monitoring performance. Finally, the project moves into a phase of ongoing maintenance, and continuous improvement as circumstances change.

In Cummins case, the project was almost worldwide and called for environmental, health and safety reporting throughout the organisation. The information was shared via a globally accessible document repository, and then processed centrally at the head office in Columbia, Indiana USA.

Measuring environmental performance almost inevitably has other benefits that make it doubly worthwhile. Speaking at the 2014 National Safety Council Congress after receiving the top award for excellence, Cummins chairman and ceo Tom Linebarger commented on a journey that was ?nothing short of amazing? yet wasn’t even a ?pathway to the finish line?.

?All of us feel like we have way more to do to make sure that our environment is as safe as it could be,? he added, ?so that our sustainability footprint is as good as it can be and that we continue to set more aggressive goals every year. That’s just how we think about it.? Linebarger concluded.

If you are taking your company on a journey to new heights of environmental excellence, then you should consider choosing ecoVaro as your travelling companion. We are environmental management specialists and have proprietary software geared to process your data. We also have a wealth of experience, and a treasure chest of roadmaps to help you achieve your goal.

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