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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Successful Engineer Communication With FieldElite

Technological innovations have been on the rise in the recent past. Our news media are awash with new technologies that are being released in almost every industry. From smart buildings to sophisticated gadgets, every industry has a technological invention to flaunt. 

One area in which technology has blossomed is the field service. In the field service management, things have moved a notch higher. Right from communication, document management, monitoring and evaluation, to information storage, nothing remains where it was a couple of years ago. You no longer have to carry clipboards around to do your inspections or pile files in the office. You no longer have to wait for your field service employees to return to the office before you can receive reports. By using a field service management software like FieldElite, you have it all done at a click. 

With FieldElite, you’ve got everything under control right from the comfort of your office. Provided you’re doing what you need to do and posting updates using the app, the rest will fall into place. Your employees will receive updates from you and vice versa. If there is a client who needs attention, they can easily issue a request through the app and the next available field service officer who?s within proximity will pick it up and attend to the customer?s needs. 

Everything is just a click away. Sounds great, right?

FieldElite is a robust field service management software that’s packed with a wide array of tools meant to simplify communication between the office and the field service employees. With FieldElite, you can reach all your engineers at one go. 

Below are a few of the communication features that make FieldElite the software of choice when it comes to field service management.

Simplified Communication

It’s very important to stay in touch with your engineers in the field to monitor the ongoing activities. For this reason, you need to choose a platform that doesn’t complicate the process. You don’t want important information to reach your team late. That would drag your activities.

Fast and effective communication is, therefore, very key in field service. FieldElite has consequently been made to simplify communication in the field service. Its simplicity can be compared to the usual consumer messaging apps. On the back-end, however, there are very many complex procedures executed through refined algorithms meant to process information and generate instant reports for engineers, supervisors, and the rest of the company team members.  

With the FieldElite app, communication is as easy as dropping a message in the team members? inbox. Again, the app?s communication system is centralised and, thus, every communication trail is easily retrievable. You don’t need different apps for messaging, audio and video calling, and document sharing. You have it all in FieldElite. Simply put, FieldElite is an all-in-one field service management tool that ropes in all essential digital modes of communication. 

But what’s the benefit of having all work-related communication in one place? 

With an all-in-one communication platform like FieldElite, you’ll cut down on wasted time and field tech frustration. Again, any urgent information will reach your engineers on time, and none of them will be left out. What’s more? With effective communication, expect the performance of your team to shoot up. 

Consistent Communication

Field technicians, in this case engineers, need to be kept on toes to get the job done. You can only achieve this by communicating with them more often. Therefore, you need a field service management platform that can offer you that. Most field service management software facilitates constant communication with team members in the field. Even so, not all are as good as you expect. So, you’ve got to be a bit more critical when choosing a field service management software for your business. 

A good field service management software is one that enables you to regularly check in with field techs to make sure that they have everything they need. With FieldElite, you can achieve more than this. FieldElite app allows you to communicate with your engineers from time to time through messages, calls, or shared documents. Again, the team gets information at the same time. 

So, how important is regular communication with your business? 

Keeping in touch with your team members in the field helps you build strong relationships with them. Additionally, you can easily spot areas that need improvement that otherwise could have been hidden from your viewpoint. What’s more? Employees feel valued when you check on them from time to time. As a result, this will boost their overall productivity, which contributes positively to the well-being of your business.

So, take your business to another level by making use of FieldElite communication tools to reach out to your engineers at any time.

Two-Way Communication

Communication in field service can only be successful if you can get feedback from your field techs. As such, the field management software should make it easier for your engineers to notify you of anything that needs urgent attention. With the FieldElite app?s communication features, your engineers can give you real-time updates from any device. The app is compatible with any android device, and, therefore, the field techs can use their smart handsets to communicate important information. 

The messaging and calling features are easy to manipulate, and with a little training, anyone can use them easily. Again, FieldElite allows you to make group calls or send many messages at the same time. Therefore, in case you?d like to talk to the entire team, you can choose to make a group call or send out bulk messages. 

Real-Time Updates

With FieldElite, you don’t need to wait until you meet your team to communicate any changes. You can notify your team on any work-related changes anytime, and as many times as is necessary. The good thing about FieldElite is that the information reaches all your engineers instantly and at the same time. Provided there?s strong network coverage, you’ll not have to deal with delayed communication. Again, your field techs can always get back to you in case they need clarifications on some matters.

Timely updates are very necessary for field service management. Field techs that get real-time updates tend to be more productive than those who get information late. At least they can make necessary changes on time to avoid wasting time on tasks that aren’t urgent. Therefore, make use of FieldElite communication features to keep your engineers updated.

Would you like to take your business to another level? Well, it’s time to improve communication with your field techs. Get the FieldElite android app for successful communication with your engineers.

How Volvo Dublin achieved Zero Landfill Status

The sprawling New River Valley Volvo plant in Dublin, Virginia slashed its electricity bill by 25% in a single year when it set its mind to this in 2009. It went on to become the first carbon-neutral factory in 2012 after replacing fossil energy with renewable power. Further efforts rewarded it with zero-landfill status in 2013. ecoVaro decided to investigate how it achieved this latest success.

Volvo Dublin?s anti-landfill project began when it identified, measured and evaluated all liquid and solid waste sources within the plant (i.e. before these left the works). This quantified data provided its environmental project team with a base from which to explore options for reusing, recycling and composting the discards.

Several decisions followed immediately. Volvo instructed its component suppliers to stop using cardboard boxes and foam rubber / Styrofoam as packaging, in favour of reusable shipping containers. This represented a collaborative saving that benefited both parties although this was just a forerunner of what followed.

Next, Volvo?s New River Valley truck assembly plant turned its attention to the paint shop. It developed methods to trap, reconstitute and reuse solvents that flushed paint lines, and recycle paint sludge to fire a cement kiln. The plant cafeteria did not escape attention either. The environment team made sure that all utensils, cups, containers and food waste generated were compostable at a facility on site.

The results of these simple, and in hindsight obvious decisions were remarkable. Every year since then Volvo has generated energy savings equivalent to 9,348 oil barrels or if you prefer 14,509 megawatts of electricity. Just imagine the benefits if every manufacturing facility did something similar everywhere around the world.

By 2012, the New River Valley Volvo Plant became the first U.S. facility to receive ISO 50001 energy-management status under a government-administered process. Further technology enhancements followed. These included solar hot water boilers and infrared heating throughout the 1.6 million square foot (148,644 square meter) plant, building automation systems that kept energy costs down, and listening to employees who were brim-full with good ideas.

The Volvo experience is by no means unique although it may have been ahead of the curve. General Motors has more than 106 landfill-free installations and Ford plans to reduce waste per vehicle by 40% between 2010 and 2016. These projects all began by measuring energy footprints throughout the process. ecoVaro provides a facility for you to do this too.

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Project Management

In a cutthroat market, where the competition is constantly on the attack to break into your market share, implementing a project-based system can give your organisation the necessary tools to be more efficient and agile.

However, rapidly changing consumer demands, technologies and other factors make it ever more difficult to generate a strategic advantage from projects, let alone develop one. Also since a large organisation can easily end up having to manage multiple projects at the same time, the new management paradigm can appear too complex.

What your company really needs is the expertise that can guide you starting from conception and planning, down through procurement and execution in order to maximise whatever resources you have. Each move must be well thought out so that there are clear goals and objectives as well as methods to achieve them.

Programme Management

Are you running multiple projects pointing to an overall strategic direction? Then you’ll need more than just a “scaled-up” version of project management to make sure every component’s work effort is well coordinated to achieve your enterprise’s desired outcomes.

Through our expertise in programme management, we’ll work with your stakeholders, executives and clients to achieve the following:

  • Design a well-articulated management structure and clearly define decision-making roles & responsibilities – This will ensure decisions are made rapidly with zero to minimal overlapping issues and to promote a unified, well-synchronised advance towards the common objective.
  • Set objectives then make sure they are met by guiding your key personnel in coordinating activities across projects.
  • Design or utilise existing financial models such that they adhere to your enterprise’s financial policies.
  • Develop procedures for reporting expenditures specific to the programme.
  • Establish the programme infrastructure, including
    • The appropriate technical environment and tools (e.g. hardware, software, communication, and other IT-related items)
    • IT staff and administrators
  • Evaluate your enterprise’s current IT architecture to determine whether it will suffice to achieve your objectives. If it doesn’t, propose options you can take to meet what is required.
  • Plan out activities that should take place in different levels in the organisation.
  • Implement a periodic review of the programme progress as well as of interim results to ensure everything is aligned with the strategic outcome.

Programme and Project Reviews

Whether we’ve helped you set up your programme or you did it on your own, time will come when you’ll need to know whether everything is going as planned. If it appears like the entire programme is going smoothly, chances are, something’s going awfully wrong somewhere. Remember, even the most well-planned projects and programmes are still under the mercy of unforeseen variables.

We’ve got highly specialised reviews for either projects or an entire programme. We’ll be able to provide you answers to questions like:

  • Are all projects aligned with the programme’s intended direction?
  • Are the people working on your projects as focused with the business rationale as they have been with meeting deadlines and utilising resources?
  • Where are your risks and exposures? How can they be remedied?
  • Is the project viable at all?

We understand how your staff would want to function normally as quickly as possible. Rest assured, our programme and project reviews are conducted swiftly and efficiently so that both interruptions and oversights are brought to a minimum.

After we’re done, you can expect a detailed quantitative assessment of your programme and/or projects’ status.

Basically, we’re not here to find mistakes; we’re here to help you find ways to correct them. If a project rescue is required, we’ll be the first to lend a hand.

Project Rescue

Believe it or not, many of our clients approached us not before or during their project’s planning stages. But rather, after having gone through sloppy execution, when they end up losing control. In other words, we’re usually at the receiving end of the distress signal, after they’ve punched the panic button.

While obviously this isn’t the ideal time to seek the aid of any expert because it means you’ve incurred unnecessary losses already, all is not yet lost. If the appropriate remedial actions are taken in a timely manner, you can still achieve highly acceptable end results.

In fact, in most of our experiences with project rescue operations, we’ve been able to put projects back on track – just the way the planners wanted them to be. We’ll also help you devise airtight strategies to prevent your project from going astray again.

At the end of our project rescue,

  • You’ll regain complete control
  • Milestones will be reached as planned
  • Requirements will be accomplished, and
  • The project will be realigned with ideal business directions

Project Governance Processes

Constructing a firm underlying structure is essential in any organisation. So before we’ll institute project management, we’ll do the following first.

  • Set up a PMO or Project Management Office to ensure, among others, that
    • Utilisation of facilities, budgets, technical support and other resources will be well coordinated
    • Work products can be tracked and reviewed
    • Issues regarding methodology and processes will be given appropriate attention
    • Training can be organised
    • Project management discipline be instilled in the IT department
  • Establish a steering committee to oversee the implementation of IT and business strategies
  • Fill up slots for a project manager, IT executive and a business sponsor and define the roles of each
  • Infuse project management practices to all affected units of the enterprise

Establishing PMOs, steering committees and other management structures is the easy part. Many organisations spend so much in order to create the structures related to project management, only to find out later that the effort has been all for naught. That’s why we won’t end there. Our objectives will therefore include the following:

  • To plant and cultivate an environment appreciative of project governance i.e. one that does not project it as just a bunch of bureaucratic processes and protocols.
  • To establish an organisational culture that starts at the top.
  • To make everyone involved understand that the power of project governance still lies in the hands of those who will ultimately implement it.

A project-driven enterprise is never propelled by a single project. Since multiple projects require a more complex governing structure, you’ll need to understand the intricacies of programme management.

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