What Sub-Metering did for Nissan in Tennessee

When Nissan built its motor manufacturing plant in Smyrna 30 years ago, the 5.9 million square-foot factory employing over 8,000 people was state of art. After the 2005 hurricane season sky-rocketed energy prices, the energy team looked beyond efficient lighting at the more important aspect of utility usage in the plant itself. Let’s examine how they went about sub-metering and what it gained for them.

The Nissan energy team faced three challenges as they began their study. They had a rudimentary high-level data collection system (NEMAC) that was so primitive they had to transfer the data to spread-sheets to analyse it. To compound this, the engineering staff were focused on the priority of getting cars faster through the line. Finally, they faced the daunting task of making modifications to reticulation systems without affecting manufacturing throughput. But where to start?

The energy team chose the route of collaboration with assembly and maintenance people as they began the initial phase of tracking down existing meters and detecting gaps. They installed most additional equipment during normal service outages. Exceptions were treated as minor jobs to be done when convenient. Their next step was to connect the additional meters to their ageing NEMAC, and learn how to use it properly for the first time.

Although this was a cranky solution, it had the advantage of not calling for additional funding which would have caused delays. However operations personnel were concerned that energy-saving shutdowns between shifts and over weekends could cause false starts. ?We’ve already squeezed the lemon dry,? they seemed to say. ?What makes you think there?s more to come??

The energy team had a lucky break when they stumbled into an opportunity to prove their point early into implementation. They spotted a four-hourly power consumption spike they knew was worth examining. They traced this to an air dryer that was set to cyclical operation because it lacked a dew-point sensor. The company recovered the $1,500 this cost to fix, in an amazing 6 weeks.

Suitably encouraged and now supported by the operating and maintenance departments, the Smyrna energy team expanded their project to empower operating staff to adjust production schedules to optimise energy use, and maintenance staff to detect machines that were running without output value. The ongoing savings are significant and levels of shop floor staff motivation are higher.

Let’s leave the final word to the energy team facilitator who says, ?The only disadvantage of sub-metering is that now we can’t imagine doing without it.?

Contact Us

  • (+353)(0)1-443-3807 – IRL
  • (+44)(0)20-7193-9751 – UK

Check our similar posts

The Types of Industries That Can Benefit from Field Service Software

Initially, field service software was designed with field techs and their managers in mind. However, in the recent past, other industries have taken this path to better the performance of their businesses. Any industry that deploys skilled laborers and assets to off-site locations benefits from field service software. It’s all about resource allocation and data centralization for efficient management and running of the business? activities. With field service software, you got all your business? functions logged in one place.

So, who needs field service management software? Professionals like electricians, plumbers, IT technicians, construction workers, and carpenters all find it useful. Moreover, there?s a wide range of application in many different types of industries.

Here are some industries that benefit from field service management software.

  • Fire and Life Safety

In a fire and life safety industry, equipment and safety systems should be kept running at peak efficiency. Therefore, it’s necessary to provide appropriate services that will ensure the smooth running of processes. On top of complying with government codes, fire and security systems installed should offer reliable services. Since service is at the core of this industry?s operation, most people in fire and security industries are turning to field service software to automate operations of their service delivery. With the field service software tools, the industry can easily monitor security technologies, quickly respond to customers, and manage compliance, inspections, and procedures effectively.

  • Medical Device Enterprises

For medical device companies seeking to improve their services, sales, and compliance, field service software becomes very essential for the smooth running and operations of their functions. The medical device enterprises that greatly benefit from this software include those offering installations, repair, and maintenance of medical equipment. With the comprehensive field service tools, service delivery and performance is greatly improved.

Moreover, with the field service software, these industries find better ways of tracking critical records needed for regulatory compliance since the medical industry is one of the most regulated industries in the globe. For the companies doing the manufacturing of medical equipment, they can integrate field service software in their accounting systems to streamline their invoice processes and shorten their billing cycles.

  • IT and Communications Services Companies

With the remarkable technological advancements in the recent past, Internet service providers, cable companies, and communications organizations are looking for better ways of service delivery to keep up with the pace of the growing technology. Connections are becoming more complex day by day propelled by an explosion in new data sources, and the use of the devices. To keep up with the increased demand for instant services by customers, the IT and communication service companies, are turning to field service software to make their service delivery more effective.

A combination of the robust, advanced scheduling system and rich functionality makes this software very useful to the communication service companies. They can use the software to design and install complex internet infrastructure. Moreover, field service software can be used by these companies to set up recurring maintenance plans to maintain the installed internet systems.

  • Oil and Gas Enterprises

Most oil and gas industries are faced by complexities which need special handling for better business performance. Since the running of projects is at the cornerstone of their businesses, they’re always looking for better ways to ensure a smooth running of their project activities. For this reason, most of the oil and gas enterprises that have discovered the benefits of field service software are integrating the main activities of their projects in this software.

With the project-based software tools, there?s an efficient flow of information and transparency throughout the enterprise ensuring excellent project management. With the checklist feature included in most field service software, inspections, compliance, site surveys, and maintenance of procedures is made easier in oil and gas companies.

  • Facilities Management Industry

Given that this is a service industry, high-level of efficiency is paramount. To meet customer expectations and battle against cost, most facility management industries are turning to field service software. With the comprehensive tools included in the field service software, supervisors can assign tasks to their reports, monitor their progress, and receive alerts on critical issues while in a remote place or at the comfort of their office.

Maintenance and emergency repairs in the facility management industry are greatly supported by this software ensuring increased productivity and efficiency. Additionally, with field service software the industries benefit from a streamlined workflow and improved communication that greatly reduces administration time and cost.

  • Industrial Equipment Enterprises

Industrial equipment companies aim at maximizing their overall productivity and preventing equipment downtime. There?s a wide range of activities that take place in industrial equipment companies which require field service software for higher levels of efficiency.

From load testing, installation projects, and load testing to emergency repairs, this software, enables the managers to design work orders, and get them ready for scheduling, and distribute them in a moment. With the equipment and asset tracking software, the supervisors can gain instant visibility into the equipment and assets in the field to ensure their regular maintenance. The scheduling and resourcing tools ensure the supervisors are in full control over the dispatching of their workforce, their schedules, and the route taken by each for maximum work output. Additionally, with the field service software, industrial equipment companies can meet their customer expectations.

  • Construction Industry

Since construction work involve both site work and office work, building industries find field service software very useful in integrating their field and office activities. Field service software is designed to establish effective communication between the office staff and the field operators. With inclusive software tools, the supervisors can easily manage daily inspections and receive feedback from the field workers without leaving the office. Moreover, documentation is simplified, and everything is documented in a central place so that it’s easier to retrieve important information at any time. With field service software, building industries can manage their construction efficiently while minimizing cost, and saving on time.

Filed service software is gaining popularity in the industrial world as most enterprises seek to improve their business? performance, and keep up with the competition. Moreover, more companies are expected to come on board as the field service software companies work extra hard to add more tools to suit a wide range of functions.

Operational Reviews

IT OPERATIONAL REVIEWS DEFINED
An IT operational review is an in-depth and objective review of an entire organisation or a specific segment of that organisation. It can be used to identify and address existing concerns within your company such as communication issues between departments, problems with customer relations, operating procedures, lack of profitability issues, and other factors that affect the stability of the business.
Operational reviews allow the organisation members to evaluate how well they are performing, given that they perform appropriately according to the procedures set by them, allocating their resources properly, and performing such tasks within time frame set and using cost-effective measures. More importantly, it also shows your company how well it is prepared to meet future challenges.
Simply put, the goals of an operational review are to increase revenue, improve market share, and reduce cost.

THE BENEFITS OF AN IT OPERATIONAL REVIEW
The main objective of IT operational reviews is to help organisations like yours learn how to deal with and address issues, instead of simply reacting to the challenges brought about by growth and change.
In such review, the information provided is practical from both a financial and operational perspective. Using these data, the management can then come up with recommendations, which are not only realistic, but more importantly, can help the organisation achieve its goals. The review recognises the extent to which your internal controls actually work, and enables you to identify and understand your strengths, weaknesses, opportunities and threats

To be more specific, let’s list down the ways wherein an effective operational review can contribute to the success of the organisation.

The review process can:
– assess compliance within your own organisational objectives, policies and procedures;
– evaluate specific company operations independently and objectively;
– give an impartial assessment regarding the effectiveness of an organisation’s control systems;
– identify the appropriate standards for quantifying achievement of organisational objectives;
– evaluate the reliability and value of the company?s management data and reports;
– pinpoint problem areas and their underlying causes;
– give rise to opportunities that may increase profit, augment revenue, and reduce costs without sacrificing the quality of the product or service.
Thus, each operational review conducted is unique, and can be holistic or specific to the activities of one department.

Our Operational Efficiencies cover the entire spectrum:

  • What to buy
  • Optimising what you’ve already bought e.g. underutilised servers, duplicate processes, poorly managed bandwidths
  • Making your team comfortable with the changes
  • Instilling Best Practices

UNCOVER WAYS TO DRIVE YOUR PROFITS UP, THROUGH OPERATIONAL REVIEWS

More Operational Review Blogs


Carrying out an Operational Review


Operational Reviews


Operational Efficiency Initiatives


Operational Review Defined

Systems Integration as a means to cost reduction

System integration in an organisation refers to a process whereby two or more separate systems are brought together for the purpose of pooling the value in the separate systems into one main system. A key component of process consolidation within any organisation is the utilisation of IT as a means to achieve this end. As such, system integration as a means to cost reduction offers organisations the opportunity to adopt and implement lean principles with the attendant benefits. The implementation of lean techniques requires an adherence to stated methods to facilitate the elimination of wastage in the production of goods and services. In summary, the lean philosophy seeks to optimise the speed of good and service production, through the elimination of waste.

While analysing some of the traditional sources of waste in organisational activities, things like overproduction, inventory, underutilised ideas, transmission of information and ideas, transportation of people and material, time wastage and over-processing stand out. The fact is that companies can eliminate a significant portion of waste through the utilisation of IT to consolidate processes within their organisation.

Adopting lean principles calls for the identification of all of the steps in the company value stream for each product family for the purpose of the eliminating the steps that do not create any value. In other words, this step calls for the elimination of redundant steps in the process flow. This is exactly what the utilisation of IT to consolidate processes offers a company. For instance, the adoption of a central cloud system across a large organisation with several facilities could increase efficiencies in that company. Such a company would drastically reduce the redundancies that used to exist in the different facilities, eliminate the instances of hardware and software purchase, maintenance and upgrade, modernise quality assurances processes and identify further opportunities for improvement.

Perhaps, from the company’s point of view, and from the perspective of lean process implementation, the most important factor is?the effect it has?on the bottom line.’reducing the number of hardware, eliminating the need for maintaining and upgrading hardware, removing the necessity for software purchase and upgrade across facilities also contributes to a significant reduction in operational costs.?This reduction in the cost of operations leads to a corresponding increase in the profit margin of the company.

Applying system integration as a means to cost reduction can also lead to the reduction in the number of people needed to operate the previous systems that have been integrated into one primary unit. Usually, companies must hire people with specialised knowledge to operate and maintain the various systems. Such employees must also receive special training and frequent ongoing education to constantly stay informed of the latest trends in process management. With the integration of the system, the number of people needed to maintain the central system will be significantly reduced, also improving the security of information and other company trade secrets.

Based on an analysis of the specific needs that exist in a particular company environment, a system integration method that is peculiar to the needs of that organisation will be worked out. Some companies may find it more cost-effective to use the services of independent cloud service providers. Others with more resources and facilities may decide to set up their own cloud service systems. Often, private cloud service system capabilities far exceed the requirements of the initiating company, meaning that they could decide to “sell” the extra “space” on their cloud network to other interested parties.

A company that fully applies the lean principles towards the integration of its systems will be able to take on additional tasks as a result of the system consolidation. This leads to an increase in performance, and more efficiency due to the seamless syncing of information in a timely and uniform manner.

Companies have to combine a top-down and a bottom-up approach towards their system integration methods. A top-down approach simply utilises the overall system structure that is already in place as a starting point, or as a foundation. The bottom-up approach seeks to design new systems for integration into the system. Other methods of system integration include the vertical, star and horizontal integration methods. In the horizontal method, a specified subsystem is used as an interface for communication between other subsystems. For the star system integration method, the subsystems are connected to the system in a manner that resembles the depiction of a star; hence, the name. Vertical integration refers to the method of the integration of subsystems based on an analysis of their functionality.

The key to successful system integration for the purpose of cost reduction is to take a manual approach towards identifying the various applicable lean principles, with respect to the system integration process. For instance, when value has been specified, it becomes easier to identify value streams. The other process of removing unnecessary or redundant steps will be easier to follow when the whole project is viewed from the whole, rather than’the part. Creating an integrated system needs some?patience?in order to work out kinks and achieve the desired perfect value that creates no waste.

Contact Us

  • (+353)(0)1-443-3807 – IRL
  • (+44)(0)20-7193-9751 – UK

Ready to work with Denizon?

Contact Us Today