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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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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How FieldElite helps Plumbers

While most people think that running a plumbing business is a very easy job, things are a bit different on the ground. The job goes beyond the dropping by a client’s home and fixing a few pipes. In addition to the actual plumbing work, a plumbing business also involves managing quotes, invoicing customers, dispatching field service workers, and accounting, among others. Undertaking all these operations manually is extremely demanding. Besides the tedious work that it is, you’re likely to end up with a ton of errors. 

However, you can overcome these challenges by employing technology. The use of field service management software allows you to automate tasks. Consequently, you no longer have to deal with paperwork, delayed responses to customer requests, or double assignment of tasks.

If you’re wondering which field service management software to use, FieldElite is your best bet. FieldElite is feature-rich, and it gives you way more than the simple automation of the daily operations of your plumbing business.  

Below are some of the top benefits you’ll reap by using FieldElite to run your plumbing venture.  

Convenient Scheduling

Scheduling is an important aspect of the plumbing industry. Just like other field techs, plumbers would require tasks to be dispatched on time, which is only made possible by proper scheduling. With FieldElite, managers can easily schedule single and recurring tasks for the right plumber in a matter of seconds. 

On the other hand, plumbers can also view the available jobs and job information in the FieldElite easy to use App that’s available for Android, and confirm scheduled jobs. They can also accept these jobs using their smartphones and respond to service requests instantly.

Apart from getting the scheduled tasks, the FieldElite scheduling and dispatch feature is integrated with GPS functionality so that plumbers can get information on where to go next, and the optimal route to take from their mobile phones. 

The scheduling and dispatch feature also gives plumbers the information on the specific tools required for the job to allow them to get the tools in between appointments and schedules. 

Central Data Storage

Just like other field service industries, plumbing also involves big data. Handling data manually would mean more errors for your plumbing business, which will only impact negatively on your business. To eliminate such errors, go paperless with FieldElite. 

You can view everything from one place with FieldElite?s dashboard feature, including information about your plumbers and the scheduled tasks. On the other hand, your plumbers can access job details and the pending tasks from a central place. 

Plumbers can also get service requests from customers on the FieldElite mobile app from wherever they are. All the requests are stored in a central place, making the response to customer requests easier. The end result is satisfied customers, opening doors for return orders. 

In case of an update, all plumbers receive notifications at the same time and, where necessary, respond promptly to the requests. They can update the office instantly with job status changes from a central place. 

Convenient Reporting

Reporting is part of the tasks that plumbers have to do after completing the assigned job. As a manager, you expect your plumbers to keep you updated on the status of each assignment. Reporting on paper is time-consuming, and that’s why you need the services of FieldElite. 

With FieldElite reporting feature, sending over completed job reports is only a few clicks away. Plumbers can generate reports on the mobile app and keep the office staff updated on the status of the job. Using FieldElite, you can capture customer signatures and add attachments to the job status and send them instantly using the mobile app available on Android. 

Since they can do instant reporting via the mobile app, the plumbers can proceed to attend to new service requests as soon as they’re done without having to first come back to the office to submit their reports. 

Effective Communication

Timely communication is very essential if you’re working with field technicians. Since you’ll not always be with them in the field, it’s always important to establish a proper communication channel to ensure information reaches your plumbers in time. Here, you can get much more with FieldElite, including communication automation to remind customers of appointments.

With FieldElite field service management software, plumbers receive notifications through the mobile app. The notifications can be for anything from new task requests, requests for alterations, emergencies, and more. On the other hand, office-based staff gets to access the reports once the plumber completes their given task. 

That means the plumbers in the field and the office-based team gets communication instantly, enabling them to see and manage their workloads. For this reason, plumbers can complete multiple tasks within a short time, thus improving their overall productivity.

Scalability

The biggest question for most entrepreneurs when they want to buy management software is scalability. Businesses grow and incorporate new activities that would also require to be managed from a centralised system. Where that’s not possible, the business would have to move all their information from one system to a more robust one. 

With FieldElite, however, you’re safe. It works perfectly well for startups as well as large-sized plumbing businesses. It allows you to focus on the areas that your organisation covers now, but also lets you add new areas as you introduce them into your business. Moreover, FieldElite is also receiving regular updates to that bring it up-to-speed with new technologies and new ways of doing things, meaning that your business will be in a position to take advantage of the latest and more productive features. 

From the benefits mentioned above, it’s quite clear that your plumbing industry greatly needs the services of a field service management software. Your plumbers too need easier time working on their assigned tasks, adding to the reasons why you need to integrate FieldElite in your plumbing business.

5 Ways To Grow Your Business | How Field Service Management Software Helps

Building up any business is already hard, more so when it involves providing field services.

A field service business owner has to manage the usual tasks, like scheduling jobs efficiently or inventory checks, and you have to do it while your employees are scattered about on various locations.

It’s the reason FieldElite was created, to provide companies with a much better way to manage and monitor their field workers.

Aside from effective management for your workforce on the move, field service management software can also help your business grow.

5 Ways Using Field Service Management Software Grows Your Business

1. Management Integration

You replace manual field service processes. If your business also uses other management apps, like CRM, payroll, industry-specific software, etc., make sure to integrate them with your chosen field service management software.?

Make those software work side-by-side with your field service management app to achieve streamlined business management.

Integration also removes the possibility of duplicate input on the regular system used and your field service management software, maximising your efficiency and business growth.

2. Improved Tracking

Utilising a field service management software gives you better tracking of every aspect of your field service business.

  • Track your inventory numbers in real-time ? know exactly how much stock is on hand for parts, and when it’s time to order more
  • Constant updates on Key Performance Indicators ? ensure your business is running smoothly
  • First-time fix rates tracking ? avoid wrong rate application
  • Monitor your technician?s performance ? ensuring quality work, in turn, profit.

Grow your business by having improved tracking on meaningful data and analytics produced from your field service management software.

3. Cost Cutting

Cutting costs can improve your bottom line and a lot of businesses turn to laying off technicians to cut costs. With a field service management software, there?s no need to go this route.

You cut costs through no manual processes needing to be completed. No need to hire back-office staff to field service calls or produce paperwork orders.

Your field service software should have all your automated needs met for efficient field job management.

An example of cost-cutting using field service app:

Track how much your technicians drive and find alternate routes for them to take.

  • Reduce gas expenses
  • Reduce repair bills for the truck
  • Finding better alternate routes can give more time to get to more jobs
  • Increased efficiency for the field technician

4.? Mobile Adaptability

Field service companies are focusing on mobility to grow their business. With a field service management software, technicians have on hand the tools and information needed to complete their job.

Field technicians can utilise the following field service software features:

  • Limit how much time they spend completing administrative work with the automated work-order management
  • Complete checklists on their mobile device and follow step-by-step instructions
  • Check service history
  • Close job orders/calls, collect signatures and start the invoice process

With a mobile app, technicians can complete a call faster, increasing the number of job order scheduled each day, giving additional revenue and that helps to grow your business.

5. Automation

What good is a field service management software without automated features??

Automation, in any industry, is an important factor in managing and growing your business.

Here are some examples of automation features and tools that your software needs in field service:

  • Create and convert quotations into work orders
  • Schedule/Reschedule jobs
  • Accept jobs in the field
  • Convert jobs into invoices
  • Preventative maintenance service
  • Customer updates
  • Automated job reports

Business Growth with your Field Service Management Software

Field service management software is growing businesses through automation, tracking and workflow management.

Your operation can run smarter and more efficiently, all while empowering your field technicians to do their job smoothly.

If you haven’t turned to a field service management software yet, you’re missing out on chances to grow your business.

Check out FieldElite to help grow your field service business today!

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