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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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Field service and its impact on your bottom line

There are many pointers to successful field service in any business. Generally, labour hours, parts, technician efficiency, performance indicators and other bunch of data are the most important. However, the icing on top is the total revenue. If you are in business, you must be cocksure that it’s making money, and when you don’t rake in enough you need to make some business decisions quick!

For the most part, field service companies will always have a field service management software to handle all the data. But how will this affect your outlook? 

Will this cause a direct increase in revenue? 

What will still need to be changed so that the ship stays afloat?

Increase your service jobs

As expected, the best field management software will guarantee a positive increase in appointments per week. On average, the field service team should expect at least a 50% increase in work turnover. There is a direct relation between the revenue you should be making and the number of calls in your schedule since the only way of making more cash is to get more work done. It is not recommended to raise costs because it increases the risk of losing customers easy when they can’t meet the extra expense. Field service software will help you bring in more customers and also manage technicians.

If you have much of the hard work done for you then you?d have more time to run the show. This is why premises are trying out software because they answer many problems like:

  • Automation and improved work order management
  • Fast dispatch from an array of drag-drop scheduling tools
  • Easy-to-use field service apps for technicians to receive and submit work orders
  • Can be integrated into account systems for faster billing time

Manual operations are costly and prone to error, and they don’t come cheap. Do away with them, reduce costs, sit back and watch as new customers steadily stream in. Grow the business by building lasting relations with your workforce and customers.

Increase technician?s abilities with mobile

If you want to get more profit, bank on technicians who complete service calls. Their task is obviously the hardest. They have an unpredictable job; at times they need to come up with quick responses or they may also be required to dig deep as well. The work does not need to be slowed with an endless paper trail while they could be elsewhere giving their all. These technicians require a working mobile field service management app.

As expected, field service leaders who use a mobile field service software report close to 20% increase in service visits per technician. This translates to each technician taking nearly a fifth more calls in a day. And as we had said before, more service calls can double the profits. How can technicians get extra time from a field service mobile app?

  • No need to drive to work to pick orders
  • Less time using the phone looking for service or parts information
  • Reduces the time needed to go through paper-based work
  • Less time driving to service calls because information is routed to their mobile phones

Increase revenue from technicians

If time is spent seamlessly, dispatchers will find time in a technician?s schedule for an extra service call. With all this being done within normal working hours, the business stands to increase its bottom line. This is what makes the business grow. Not by increasing technicians but by optimum utilisation of the current staff to get maximum profit. The logic is straightforward ? a technician working 8 hours each day taking six calls a day will make more revenue than the one who takes four, because they are paid the same each, but the business benefits from the extra service calls.


The business stands to make more revenue per technician if it uses field service management software. The margins can go as high as 40% because the technician has all tools needed to get the job done faster. You increase revenue from field work too. Let technicians benefit from automated process and have all the tools for work that they need right on their mobile devices.

The target is always your bottom line

When field service leaders inquire about field service software, they need to know how it affect the bottom line: how they will spend less time drafting schedules, how each technician will increase revenue, how the business will grow. Simple as that!
Field service management applications bring a lot to the table. 

Don’t waste your time crunching a lot of numbers or sorting out schedules since this is what such an application should do. Automation, optimisation and mobility are all ways of increasing revenue. Let us help you reach your goals using our top shelf field management software. This will not only help your bottom line but will let you have more time to venture into untapped potentials.

What is work force management?

For organisations to ensure they provide the right service.  In order to do they need to assign the right employees with the right skills to the right job at the right time to meet demand.

Workforce Management Background

Workforce management (WFM) is a strategy used by companies to increase their efficiency and performance. It entails all activities aimed at maintaining a steady output, such as human resource management, forecasting, field service management, budgeting, scheduling, performance and training management, analytics, recruitment and data collection.

Workforce management utilizes a unique set of performance enhancing tools and software to bolster corporate management, workers, and other categories of managers and supervisors in the manufacturing team, distribution, transportation, and retail operators. This is sometimes called HRM systems, or part of ERP systems, or workforce asset management.

Unlike the conventional outlay that only needed staff scheduling to improve time management, workforce management is now all-inclusive and demand-oriented to optimize staff scheduling. Apart from focusing on demand-orientation and optimization, workforce management also incorporates:

  • Estimating the workload and resource utilisation
  • Job scheduling
  • Management of working times and accounts
  • Monitoring the process of workforce management

Each task should be clearly defined and performed efficiently based on set engineering standards and methods of optimizing each task as much as possible. Out of this framework and demand based forecasts, workers are scheduled and given tasks, performance measured, give feedback, and incentives computed and paid.

Workforce management is an entire scheme aimed at building the capacity of workers, increase productivity and client relations, and where possible reduce labour costs.

What is Mobile Workforce Management (MWM)

Mobile workforce management (MWM) is a software-based service used to oversee employees outside of the institution?s premises; MWM sometimes refers to the field teams. Mobile workforce management encompasses all activities done to monitor and schedule the field workforce.

The entire process includes procurement, management and using mobile devices, applications and computer software. Related support services like tracking, logging, dispatch, productivity management, and other types of communication are also to make it efficient.

Companies do not have the same needs and MWM firms need to fine-tune their software and devices to sufficiently bridge this gap. Some providers are suited only to a specific type of company because of specialization, like managing the electric grid. This experience makes the MWM company suited to provide applications that are relevant to the company for them to continue operating smoothly and efficiently.

With the increase in mobile devices, applications, secured wireless networks and virtual desktop, there comes a stream of opportunities for small and medium-sized businesses (SMB) and other ventures. Nevertheless, a mobile workforce needs better controls, security and support, as well as a functioning mobile workforce management strategy.

MMS (managed mobility services) is often used interchangeably with MWM, but they should not be confused. MWM is related to software and applications used by mobile and computer devices to manage on-field work while MMS focuses on enterprises, and is like a way of keeping in touch with the company, other employees, and linking the mobile while at work to servers and the database.

Benefits of Mobile Workforce Management

MWM allows the utilization of technology to drive productivity. Here are the top five advantages of MWM..

  1. Customer focused. The customer is the backbone of any business. The team needs to keep in touch with up-to-date information about every interaction. In the end, better client relation makes sure that the customer is always happy.
  2. Information has the power to build or destroy. A cloud-based system is easier to manage and can help with collection of data which is used to make business decisions. This can help cut costs, increase the workforce support, and identify areas where polishing needs to be done.
  3. Improved efficiency. Mobile workforce management is majorly used in taskforce allocation. If the company adopts a cloud-based work force management system, allocation is done automatically saving a lot of time.
  4. Increased revenue. Each business seeks to maximize the profit. With cloud-based mobile workforce management some operations like task management, data analysis, customer communication, reporting, and performance monitoring can be automated. This reduces the costs incurred for multiple applications and saves time.
  5. Ease of communication. Communication is vital. Constant communication with customers drives sales rates and everyone loves that. Quick communication will help customers solve their problems faster and get instant feedback.

Additional WFM benefits

 Other WFM benefits are:

  • Operations are made efficient as all complex processes are automated.
  • Employers learn more about worker engagement, productivity and attendance, allowing them to modify training, coaching and processes aimed at streamlining performance.
  • Automation and easy manipulation of data to improve HR, productivity and slash administrative costs.
  • It increases employee productivity by reducing absenteeism and late arrivals.
  • Boosts the morale of employees by encouraging transparency and facilitating manager-employee communication.
  • WFM analyzes market and schedule requirements to pick the right employee with the best set of skills for a certain task.

Companies which embrace workforce management and mobile workforce management have a higher operational efficiency. They have lower operational costs and limit manual work as much as possible

Align IT Investments With Organization Goals

While some organisation leaders loathe spending on IT, a growing number are already convinced of the necessity of investing in it. Unfortunately, a substantial fraction of those convinced to pursue IT investments are misguided as to which initiatives are really contributory to reaching their organisation’s goals.

In the end, many of their purchases either end up underutilised or become white elephants altogether. There are also those difficult to spot – IT purchases that do become integrated into daily operations but have little effect on the organisation’s growth, positioning, profitability, or efficiency.

If a purchase is to cost your company a fortune, then its positive impact on established company objectives should reflect accordingly. But how would you know it would? You can’t hope to foresee all its benefits especially if the IT solution is still quite new to you.

Our job is not only to identify the strengths of an IT system but also to determine whether these strengths are at all useful to your organisation’s thrusts.

Basically, here’s what we’ll do:

  • Conduct a rigorous analysis of your organisation to determine the specific and overall impact of certain IT solutions. We’ll be looking for areas where the effects of IT can result in the most rapid reduction of costs and, at the same time, drive the organisation in the direction of its established goals.
  • Propose cohesive best-of-breed solutions in line with the results of our analysis. Our familiarity with the IT landscape and our extensive selection of contacts in the industry will allow us to conduct insightful picks from a vast field of choices.
  • Establish best practices to make sure IT investments are optimally utilised.
  • Perform periodic reviews to ensure practices and processes are still in line with the established goals.

Find out how we can increase your efficiency even more:

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