Improve manufacturing operations and cut costs by setting operational efficiency KPIs.
In the last 3 months the global economy has been turned on it’s head due to the Covid-19 pandemic. In light of this, manufacturers are faced with the pressures of producing more high-quality goods, with less money, time and resources. Regulations are becoming more stringent and competition is growing in a smaller market.
To achieve the goals of lean operation, industrial manufacturers need to constantly monitor, benchmark and improve.
KPIs can prove a valuable gauge of progress, helping manufacturers to set and achieve their business goals and maintain critical business resiliency.
1. Optimise maintenance schedules
Many manufacturers still operate preventative maintenance schedules. Preventative maintenance is costly because only 15% to 20% of all components fail after a predictable time. Reducing operational costs means approaching maintenance in a new way.
A predictive maintenance program – servicing machines based on need-based early stage notifications – is much more efficient than a Fixed Time Maintenance (FTM) Preventative Program.
This allows manufacturers to be proactive, rather than reactive when it comes to equipment repairs and operational downtime. They can make informed decisions, based on transparency and a pattern that is most suitable to their business.
Reduced costs and eliminated outages should be demonstrable when manufacturers transition to a predictive maintenance mode and track overall downtime.
2. Improve true downtime cost (TDC) and downtime percentage
Consider the true cost of unplanned downtime. Do you know what the cost of downtime is to your business? Decreasing downtime and improving operational efficiencies can save manufacturers millions of dollars.
By calculating your True Downtime Cost and showing measured improvements in this realm, you can illustrate saved time and money, as well as reduced waste and create a data-driven, quantifiable resiliency plan.
Understanding true costs can also help you to make cost justification within day-to-day management decisions.
3. Improve Rolled Throughput Yield (RTY)
RTY is the probability that a single unit can pass through a series of process steps free of defects. Acceptable Rolled Throughput Yield is dependent upon a very high individual first time yield for each process. It is the sum of the parts measurement that is most critical to overall operational efficiency.
RTY is a great operational efficiency KPI to track as it alerts manufacturers to the health of their entire operation, rolling all processes into a single measurement.
4. Maximizing capacity utilisation
Diminish the cost of owning and maintaining equipment by using equipment to its full capacity.
By measuring the output that is actually produced and comparing it to its potential maximum output, manufacturers can understand the efficiency of their operation. Increasing capacity utilisation increases overall efficiency.
An OEE score presents “an accurate picture of how effectively your manufacturing process is running. And, it makes it easy to track improvements in that process over time.”
Conclusion
These Operational Efficiency KPIs will give you an indication of the overall efficiency of your operation and a real sense of your resiliency needs.
Any downward trends in performance will require deeper analysis. Manufacturers should also look at processes, systems, and the performance of equipment.
With improved visibility and intelligent use of smart technologies throughout the plant, manufacturers can take a leap forward when boosting operational efficiency throughout the business. Using real-time data allows you to plan, in a quantifiable way, the need for a backup plan.
Talk to us to learn more about how energy insights can drive your energy and resilience strategy.
If you don’t know precisely how, when and where energy is being used across your business, how can you understand where your energy costs really lie, or the best opportunities to improve energy and operational performance?
Working together with Centrica Business Solutions, Total Utilities is the exclusive partner delivering the Energy Insight product solution to the New Zealand market. Using Centrica’s wireless sensor technology, you can monitor energy usage in real-time – right down to device and equipment level. When this information is relayed to our PowerRadarTM analysis platform, you can access the intelligence you need to develop a data-driven energy strategy.
The Power of IoT
Our Internet of Things (IoT) technology is providing the deep energy insights that uncover flexibility and value in your operations and generation assets. This is a ‘game changer’ in raising energy performance across all types of organisations – from manufacturing and leisure – to healthcare and education.
Energy Insight technology provides full visibility of energy usage across your site, or multiple sites – right down to individual device level. We attach self-powered, wireless sensors to equipment and processes, such as conveyor belts, lighting circuits, chillers, or any other energy consuming assets.
This instantly transmits real-time data to our cloud-based PowerRadar analytics and reporting platform. You can then access this intelligence to inform your decision making and improve efficiencies.
Deep energy insights
Hundreds of sensors, which can measure both heat and power consumption, can be installed within a few hours and won’t cause disruption to operations. Data provided by our IoT technology enables organisations to quickly identify and resolve energy waste. It can also pinpoint opportunities to reduce high peak-time energy costs by moderating consumption in these periods.
The biggest gains of IoT energy insights are often seen in improved operational efficiency and business resilience. By ensuring that critical equipment is operating optimally and preventing costly disruption, or even breakdown, large operational cost savings can be achieved. Continuity of operations is also assured, which is particularly beneficial in manufacturing environments.
The results of IoT energy optimisation
We’re seeing the positive results of our IoT enabled energy optimisation across all business sectors, including Progressive Enterprises New Zealand.
Join us on Monday as we discuss how the Internet of Things is changing Energy Management and how insights can support sustainable business. Register here.
Only half of new New Zealand businesses survive longer than ten years and even then, only 5 per cent of those ever reach a turnover of $1 million. That is bad news.
The good news is that of the 5 per cent of businesses that reach $1 million turnover, one in four grow to $10 million turnover.
As a start-up, finding the right strategies, tactics and culture to grow profitably and sustainably will put you into an elite group of businesses – the long term winners. Below is some advice to help you get started and survive.
A bird in hand is worth two in the bush
How many times have you heard stories about companies offering special pricing and better products to win new customers, yet they continue to overcharge loyal customers for older products and services? It costs five times as much to win a new client as it does to keep an existing one.
Value your staff
Keeping good people is about respect and values. A friend recently recounted a tale of a boss who took him for granted. One day this boss asked, on a whim, for him to change then redo a job that he had spent weeks working on. This is what the worker had to say: “That was the day I mentally left that company. It was a year before I found the right job to go to, but the decision had been taken twelve months before. They offered me better money and benefits to stay but it was way too late for that.”
Avoid profitless prosperity
Just because a deal is big it doesn’t make it worth doing. It’s okay to walk away from any bad business. Handing these kinds of duds over to your competitor can be good for your business. It frees you up to provide awesome, profitable products and services to clients who value them.
Don’t be a bank
A quarter of all debts that go past ninety days overdue are never paid. This rises to over half at 120 days overdue. Look at this another way. an unpaid debt of $1 means you will need to generate $10 in new revenues just to make up for it if your net profit is 10%.
If you have tried all reasonable ways to collect debts to no avail, then send a final warning in writing. If this fails, then using a reputable debt collection agency is a perfectly valid option. If this seems drastic, then remember it is your money and your company. Only you get to choose who keeps both.
Get good advice
Developing the skills and contacts to ensure you can reach out to the right expert at the right time is an essential craft in helping your business succeed. Getting good advice may seem expensive on occasions but can save you a world of pain in the long run. EMA offers fantastic advice to members in several key areas, at very reasonable or even no charges.
Plan for the Future
Many great businesses end up on the market having reached the stage where age or ill health have forced the owner to sell. Having a mix of ages, skills and personalities within the leadership of your company is a must. The energy, enthusiasm and contemporary relevance of youth is a potent partnership when combined with the hard-won experience of age.
My business partner Richard and I look forward to when we get to sit in the balcony seats of Total Utilities, cantankerously muttering and critiquing our new generation of leaders just as Statler and Waldorf do on the Muppet Show. The trouble is, of course, that no one will be listening.
All the best for 2020. May you live long and prosper.
Why cloud is crucial for a sustainable business, and how to choose the best option.
The Covid-19 outbreak has reinforced two lessons for businesses – the importance of cloud-based services and the need to ensure their model is sustainable. Cloud platforms have really come into their own, providing accessibility for remote workers and customers, while providing the ultimate scalability for businesses facing an uncertain future. But in a world where both the economy and environment are facing unprecedented challenges, it is more vital than ever for business owners and CFOs to make informed business decisions.
Choosing the right cloud option can be daunting, and a truly sustainable business needs a clear understanding of the financial and business case drivers to help make the right decisions.
Review the business model
Changes are happening at a rapid pace in today’s business environment, with many companies looking at downsizing and improving their remote working capabilities. Even beyond the extremes of a pandemic, acquisitions, new ventures, upturns and downturns all provide daily challenges for senior managers.
Nothing illustrates how quickly the business environment can change as the infographic below.
The infographic shows the vast drop in consumption of electricity since Covid-19 hit New Zealand. Many businesses were unable to operate from their normal offices and stores. While most have adapted to working from home, the shutdown had a huge impact on commercial electricity consumption.
While major industry consumes a third of all our energy, the wider commercial sectors consume a further quarter of New Zealand’s electricity demand. It is this quarter that we can reasonably assume to have almost completely evaporated when the lights went off.
Although the future is opening up and consumption is starting to rebound, businesses are now focused on new ways of consuming energy or delivering services.
Many CFOs and CIOs are trying to figure out this new way of working and how it affects their own businesses. The days of the road warrior salesperson may be coming to an end. How we engage with, incentivise and add value to our clients will look very different, as some may prefer a call from the office or a virtual meeting to a corporate lunch. Customers too will be feeling the impact, with online engagement becoming the predominant form of communication, and Microsoft Teams, Zoom, and Hangouts becoming an integrated part of working culture.
In addition, Covid-19 has caused a large shift in the global economy and supply chain. Secure production and supply are increasingly of greater importance than the cheapest or most efficient options, which has led to a greater focus on in-house production, multiple suppliers or regional stockpiling.
The result of all this is we can no longer trust the stability of the surrounding environment. While we may see some return to the old ways of working, some business processes will never be the same again. Business managers therefore need to be prepared to constantly review business models and consider whether their technology needs are still being met by their current system. This will help ensure their business remains sustainable in a world that can change drastically in what seems like a second.
Plan for the rebound
Kiwifruit producer Zespri is a classic example of how to approach this kind of situation. In 2010, it was dealing with the PSA Virus, which caused entire crops of kiwifruit to fail. The popular gold kiwifruit was the most affected variety, spurring Zespri scientists to research a resistant strain.
They knew the situation could have gone either way – with the opportunity to double production if the new strain was successful or ultimately halve if the research failed. Zespri was concerned about having enough computing power to cover existing demand while preparing for both the best- and worst-case scenarios.
With support from Total Utilities to assess its existing IT costs and consumption, Zespri was given a list of options that projected the business outcomes and costs for each. It could either continue managing and maintaining its own data centre, outsource its data to another local vendor, or switch to the public cloud so it could replicate the same platforms around the world. Zespri chose the latter, moving its infrastructure and associated platforms onto the Microsoft Azure Cloud.
This decision helped Zespri cover a multitude of potential problems by removing the financial risk of investing in its own tech infrastructure, allowing rapid expansion of a global supply chain and delivering detailed cost control mechanisms. Providing Zespri with financial operations toolsets allowed it to efficiently manage costs and consumption, which was repaid as Zespri’s research gamble paid off and the business grew in scale. Measures such as “cost per tray of kiwifruit shipped” have become an important way of tracking success. Zespri has used subscription cloud services as an effective way to manage, analyse and contain its costs ever since.
Not only does that mean Zespri is able to adapt its model to any scenario, not having a data centre on site reduces both energy consumption and space. The business is therefore more sustainable in every sense of the word – something consumers around the world increasingly expect. Microsoft itself has committed to removing all carbon it has ever emitted directly or by energy consumption from the environment by 2050, reinforced by its pledge to support New Zealand’s sustainability goals through its new datacentre investment. As every organisation on the planet is challenged to review its impact on the environment, choosing greener IT options is a great way to minimise your footprint.
As the adage goes, the only certainty in life is change. While an upfront investment during downturns can be daunting, the best way for any business to safeguard its sustainability long-term is to invest in an IT system that doesn’t become obsolete, that meets modern expectations around environmental impacts and which allows workers the greatest accessibility in an era when many of us are now working remotely. And that means embracing the cloud.
Ensure resilience
A resilient network and good technical support are essential to every modern business. There is an expectation for email, purchasing or sales automation to be working around the clock. Software updates, testing or hardware failures are no longer an excuse for disrupted services, which can instantly see customers go elsewhere.
Just five years ago, businesses were put off moving their platforms and operations to the cloud because they weren’t sure about achieving the level of compliance and technical competence they needed to operate the systems. Every business we consulted felt the skills to manage cloud migration were a barrier to digitising their operations, and that only in-house experts could provide the support needed. That figure is now just 40 per cent. Trust in the cloud and cloud providers to manage their businesses and tailor their services to their needs has skyrocketed.
Likewise, secure and reliable connections are more available than ever. While some thought the demand put on the internet during this period of working from home wouldn’t hold up, the Covid-19 lockdown has proven how resilient the internet can be. It is a credit to our network providers, whether fibre, copper or mobile data-based, that these services have remained largely in place as millions of people have suddenly put tremendous demand on capacity.
This shows that network availability is no longer a constraint holding back businesses from placing their operations and services in the cloud. Those organisations using public cloud services are also better placed to combat the predatory players who sought to take advantage of the situation via scams and cyber-attacks, with regular security upgrades not available to those using an outdated server in the back office.
No longer can you place your trust in simply ‘doing it yourself’. Instead, managed cloud-based services can prove more secure and reliable. Security and connectivity is complex to establish and even more challenging to maintain, especially when scarce, skilled resources are in high demand.
Establish good financial governance
Whichever cloud service you use, make sure to choose a partner or platform that can provide real-time analysis and reporting so you can see exactly how it’s working for your business and change your plan if you need to.
Governance, cost control and resource efficiency have always been top priorities for businesses. Now more than ever, businesses are focused on getting the best value for money from their technological solutions while growing a sustainable business. One thing cloud-based platforms do very well, thanks to their sheer accessibility and ease of use, is enable workers to use a huge range of resources and implement their own changes and updates. However, if unconstrained, this can result in wastage and bill-shock.
While governance and budget setting have provided the framework for cost control and planning for decades, moving to the cloud requires a new level of collaboration between Finance and IT. Ensuring these two teams remain communicative through the cloud integration process is vital to ensuring it runs smoothly and efficiently, that the right functionality is baked in from the beginning and there are no budget surprises.
As well as close co-operation, the key to ensuring total visibility and that cloud services are providing the best value, is using a monitoring service to provide real-time data on how cloud is being consumed across the business. The best services can illustrate exactly how resources are being used – either energy or data – and enable CFOs and other decision-makers to rapidly change to new plans that are better for the environment and the bottom line. Clear and regular reporting is essential and takes a great deal of time and effort out of maintaining good governance.
Cloud is the future of many businesses and in a time of so much change and uncertainty, it is important to know your business has a model it can rely on to save costs and make governance far less onerous. To know that your business is making most of out your cloud service, make sure you have reporting in place so you can accurately reflect usage in real time, limit your expenses and energy consumption and create a business model that’s truly sustainable for many years to come.
Create a sustainable energy strategy, and build a competitive advantage with powerful energy insights that provide complete visibility of your energy footprint.
Now more than ever businesses globally are looking for wastage and holding utility costs to account by requiring detailed operational reports.
As the owner of your energy strategy, it is imperative that you have end-to-end visibility of your energy footprint. Obtaining this level of visibility will provide you with energy intelligence around consumption and performance of on-site assets. These energy insights will give your business the ability to:
Understand how energy is being used across your entire footprint
Identify processes and specific devices where energy is being wasted
Manage risks and opportunities in real-time to ensure performance of assets
Manage all your data in a single energy management system
Having a centralised view of your entire energy footprint and device-level data eliminates the time and complexity involved with managing energy data in multiple platforms. A single platform that integrates with other systems creates a holistic view of your energy infrastructure that can be used to inform a single, full report.
In addition, using a single platform to manage your energy data means you always know that you’re looking at real-time, accurate intelligence. This can help you make data-driven decisions about your energy strategy that are based on the most up-to-date energy data displayed in the energy management platform.
The granular level of intelligence provided by device-level data will provide you with a deeper understanding of your energy use and help to accurately form your energy strategy. This information can be used to identify ways to future-proof your strategy to:
Improve operational efficiency
Uncover growth opportunities
Unlock new revenue streams
Identify new energy technologies
Use Energy Insights data to improve operational efficiency
Data can help your business analyse capital equipment to identify inefficiencies and determine when equipment should be replaced or requires maintenance. By keeping equipment working efficiently and performing at its optimum level, you can avoid costly downtime and reduce business risk.
Use data to uncover growth opportunities
Better energy insights can free up resources to support growth initiatives, turning energy from a commodity cost to a value-adding resource. Growth opportunities can also be achieved when your strategy successfully lowers the costs associated with energy.
Use data to unlock new revenue streams
The information gathered through end-to-end visibility can help your business leverage its energy use, flexibility and existing assets. This opportunity unlocks new revenue streams for your business by allowing you to curtail energy use or sell surplus energy back to the grid through Demand Response (DR), demand management and asset optimisation.
Use data to identify new energy technologies
End-to-end visibility of your energy footprint can help to inform decisions on using new technologies such as solar and battery storage, back-up power generation, or cogeneration (also known as Combined Heat and Power or CHP) to help drive energy optimisation and improve resilience.
The visibility of your energy footprint will grow as you adopt new technologies, but by using a centralised system to holistically monitor and manage your data, this should not add any extra complexity. In fact, your energy management system can provide you with the data you need to justify your investments in on-site energy generation.
Why businesses need to choose the right platform and provider
It is imperative that businesses partner with a provider that has the right energy insight tools and a platform that collects and centralises granular, device-level data.
Working with Total Utilities, businesses can be sure that they’ll benefit from experience and expertise. We are the New Zealand providers of Centrica’s Energy Insight solution and integrated energy management platform, PowerRadar®. These tools are generating new opportunities across all types of industry, giving organisations the ability to manage real-time, device-level energy intelligence in a single, holistic view.
Contact our experts to find out how we can help you obtain real-time visibility of your energy performance and develop a strategy that turns your energy into a competitive asset.
