FUJIFILM Cracks the Energy Code

FUJIFILM was in trouble at its Dayton, Tennessee plant in 2008 where it produced a variety of speciality chemicals for industrial use. Compressed-air breakdowns were having knock-on effects. The company decided it was time to measure what was happening and solve the problem. It hoped to improve reliability, cut down maintenance, and eliminate relying on nitrogen for back-up (unless the materials were flammable).

The company tentatively identified three root causes. These were (a) insufficient system knowledge within maintenance, (b) weak spare part supply chain, and (c) generic imbalances including overstated demand and underutilised supply. The maintenance manager asked the U.S. Department of Energy to assist with a comprehensive audit of the compressed air system.

The team began on the demand side by attaching flow meters to each of several compressors for five days. They noticed that – while the equipment was set to deliver 120 psi actual delivery was 75% of this or less. They found that demand was cyclical depending on the production phase. Most importantly, they determined that only one compressor would be necessary once they eliminated the leaks in the system and upgraded short-term storage capacity.

The project team formulated a three-stage plan. Their first step would be to increase storage capacity to accommodate peak demand; the second would be to fix the leaks, and the third to source a larger compressor and associated gear from a sister plant the parent company was phasing out. Viewed overall, this provided four specific goals.

Improve reliability with greater redundancy
Bring down system maintenance costs
Cut down plant energy consumption
Eliminate nitrogen as a fall-back resource

They reconfigured the equipment in terms of lowest practical maintenance cost, and moved the redundant compressors to stations where they could easily couple as back-ups. Then they implemented an online leak detection and repair program. Finally, they set the replacement compressor to 98 psi, after they determined this delivered the optimum balance between productivity and operating cost.

Since 2008, FUJIFILM has saved 1.2 million kilowatt hours of energy while virtually eliminating compressor system breakdowns. The single compressor is operating at relatively low pressure with attendant benefits to other equipment. It is worth noting that the key to the door was measuring compressed air flow at various points in the system.

ecoVaro specialises in analysing data like this on any energy type.?

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Is Your Project Agile, a Scrum or a Kanban?

Few projects pan out the way we expect when starting out. This is normal in any creative planning phase. We half suspect the ones that follow a straight line are the exceptions to the rule. Urban legend has it; Edison made a thousand prototypes before his first bulb lit up, and then went on to comment, ?genius is 1% inspiration, 99% perspiration?. Later, he added that many of life’s failures are people who did not realise just how close they were to success when they gave up.

So be it to this day, and so be it with project planning too. There is no one size fits all approach when it comes to it. Agile, Scrum and Kanban each have their supporters and places where they do well. Project planning often works best when we use a sequential combination of them, appropriate to what is currently happening on the ground.

Of the three, Agile is by far the most comprehensive. It provides a structure that begins with project vision / conceptualisation, and goes as far as celebration when the job is over, and retrospective discussion afterwards. However, the emphasis on daily planning meetings may dent freethinking, and even smother it.

Scrum on the other hand says ?forget all that bureaucracy?. There is a job to do and today is the day we are going to do it. Although the core Agile teamwork is still there it ignores macro project planning, and could not be bothered with staying in touch with customers. If using Scrum, it is best to give those jobs to someone else.

The joker in the pack is Kanban, It believes that rules are there to substitute for thought, and that true progress only comes from responsible freedom. It belongs in mature organisations that have passed through Scrum and Agile phases and have embarked on a voyage towards perfection.

That said, there can be no substitute for human leadership, especially when defined as the social influence that binds the efforts of others towards a single task.

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.

Be pound poor and become Penny rich

Energy management is and should be perceived as a long-term investment by organisations. Having said this, the need for all organisations to implement energy management strategies now cannot be overstated as these strategies will save their costs of running the business in future.

Many organisations may shy off from implementing energy efficiency measures in place opting to save the associated costs or to use the cash for other projects that may be perceived as high priority in the short run. This is most likely to occur when cost cutting is a priority. Long-term planning is however critical for energy efficiency programs. Taking steps to improve building management and energy efficiency will and does pay dividends in the near-term and may be a competitive tool in the long-term.

Be energy smart
All energy management projects begin with being energy smart which calls for the understanding of energy usage. Use of Smart Meters that give real time readings of energy usage, can dramatically help businesses understand the benefit which energy management brings to the organisation.

Smart meters also cut the amount of time businesses spend on administration by allowing them to pay accurate bills, based on accurate readings. Some suppliers also support businesses to identify areas of energy wastage/inefficiency and help setting targets for energy reduction that guide behavioural change with regard to energy in the organisation.

Use of technologies that record the energy usage at the water or electricity meters putting data into a system where the users can graph it has made it easy to compare energy consumption in various departments, sites or buildings. Appropriate measures can then be implemented to improve the efficiency.

Partnerships between businesses and energy suppliers
Since the long-term benefits of reduced energy consumption is beneficial to both suppliers and consumers; the responsibility of managing energy consumption is being taken by both. Businesses should work with the suppliers on cost reduction strategies through identifying areas where energy is being wasted and advising businesses on how to save energy. Of key importance when choosing an energy supplier therefore is their depth of understanding of a business’ energy management needs.

Capitalise on government incentives
Businesses should always explore varied financing mechanisms for their energy efficiency programs e.g. government schemes generating electricity and selling it to the grid.