How to save up to 10.000 € on one machine in the company.
The article describes how a company dealing with the maintenance of facilities, thanks to the awareness of how the equipment works, can potentially save €10,000 on one machine. This would not be possible without monitoring. We are convinced that monitoring the work of machines and their operators will bring measurable benefits also in other industries.
Potential savings areas based on analysis of data from the cleaning company
The analysis was carried out on the basis of data from 10 cleaning machines in a nationwide company providing, among other things, cleaning services on large-area facilities. On the basis of the data, it was possible to determine 5 areas, on the basis of which it is possible to generate savings from 6 to 40 thousand PLN on one cleaning machine. This means that the return on investment in the system monitoring the work of the machines will be achieved within the first 2 months of the system operation.
The same savings can potentially be generated in any company with any machine park.
Too big machines on objects
The above report shows the working time of Karcher B150 cleaning machines on three different objects (Warsaw, Katowice, Sosnowiec). Based on the working time we conclude that the machines in green and orange objects are too efficient in relation to needs. Because the same machines on the blue object worked up to 107% more (blue object in relation to green object). The proposed solution is to replace the machines with smaller, cheaper machines, which are correspondingly less efficient, which gives a saving of 5,000 € per machine.
Too many machines on site
The above report shows the daily time of switching on the machines at one facility in Poznań. It shows that the total time of switching on the blue machine is less than 3 hours during the whole month. The conclusion is simple: this machine is redundant there, and if a spare device is required there, it would be a good idea for the owner to insert a cheaper machine into the facility in order to optimize resources. Savings of 5,000 € - 10,000 € for each reduced machine depending on the solution adopted.
Inefficient use of machinery
In the graph above, blue indicates the driving time of the cleaning machine and red indicates the operating time of the same machine in one day. The graph shows that the machine is working less than 50% of the time it is running. Conclusion: the machine can be used for purposes other than cleaning, e.g. to move around the facility. Savings of 500€- 700€ per year on the machine due to less maintenance and less equipment wear.
Battery charging too often
The above diagram shows the level of charge of the cleaning machine battery. From the sudden voltage increases it can be seen that the machine has been charged 2 times in one day. Repeating this behavior will result in a significant reduction in battery life and will require premature replacement of the battery. By monitoring such incidents, cleaning companies can draw consequences for operators who engage in such behaviour. Potential savings in eliminating such events are 1,000€ per year per machine.
Wasting time reporting on machine operation
From the information we have in the sample company, the work of the machines is manually reported every day and saved on a piece of paper. With cautious assumptions: The total reporting time for all employees (cleaning, supervising, administrative) on 1 machine is 15 minutes per machine. Each of these employees earns a minimum salary (2600 PLN gross, i.e. 3 132 PLN of the employer's total costs)The month of work is 20 days, i.e. 160 hours, which gives 1 man-hour cost: 19,56 PLN.That is: 0,25h * 19,56 PLN = 4,89 PLN savings per day, it gives 4,89 PLN * 20 = 97,86 PLN savings per monthA subscription to the EBKF Manager work monitoring system is 19 € per month, subtracting the amount of the subscription from 97,86 PLN it gives 58,86 PLN savings per month, that is 706,32 PLN savings per year on time reporting alone. This is a cautious assumption, because the minimum wage in 2020 was taken into account in the calculation, additionally it can be assumed that according to the government's assumptions the minimum wage in Poland is still to increase from 2021.
Saving on reporting on machine performance in the first year alone will result in a return on investment. In the second and each subsequent year, the assumption of monitoring machine operation will be a pure profit. In addition, thanks to the optimization of business processes in the company, it is possible to make a casting in the scope of duties of a part of the company's staff.
The company has too many and too big machines in relation to the work performed. It is possible to replace the machines with smaller ones, i.e. cheaper ones, or to resign from machine parts.
Using the above information the company is able to save from €1,500 PLN to €10,000 PLN per year on one machine. Additionally, thanks to the optimization of business processes, it is possible to optimize employment.
The above information would not be possible to obtain without the implementation of automatic monitoring of machine work.
The implementation of RFID readers identifying employees on the machines potentially increases the possibility of process optimization.