For over a decade, FluidIntel has been implementing AdaptFMS to help clients maximise their fuel efficiency and improve their bottom line.
Here are 10 examples of how FluidIntel can help you reduce costs and maximise productivity:
Before installing AdaptFMS, one of our major clients had no accurate data regarding their fuel usage, stock or deliveries, and so were consistently purchasing and storing far more fuel than was necessary. Now, thanks to AdaptFMS, the client has tank gauges connected to real-time reporting software, meaning they can easily determine their fuel tank storage volumes at any time. As a result, the client lowered their day tank holdings from eleven million litres to nine million litres in the first six months of the project, improving their cash position by an impressive $2 million.
Manually checking and ordering fuel can be time consuming and laborious. For one of our clients, with several geographically dispersed sites, it was becoming a major burden, with staff required to drive long distances simply to check and report on their fuel tank levels. Since installing AdaptFMS, the client has been able to delegate the entire re-supply process to their fuel supplier. The system is entirely cloud-based, meaning the vendor can access accurate, secure and detailed fuel data at any time. The client expects that savings in labour costs will very quickly and easily cover the cost of installing their new AdaptFMS system.
Maintenance is one of a mine site’s largest costs. However, having vehicles out of production for unnecessary servicing is potentially avoidable. For this reason, we developed a reporting function for one of our clients, which helps them ensure their equipment and vehicles are serviced according to their fuel consumption rates rather than their time in the field. The more fuel that is consumed indicates how hard the equipment has worked. The report also collects and measures lubricant and coolant consumption, which can also indicate a higher workload. For a typical mine site, maintenance costs can be around $100 million a year. A mere 3% reduction due to more effective scheduling, can equate to an enormous saving of around $3 million per year.
To cut fuel costs, it’s vital you understand exactly how and where fuel is being consumed. When of our client was having issues reconciling the fuel volumes they were invoiced to the volumes they consumed, they turned to FluidIntel. We installed a full fuel management system, including AdaptMACs, at all of their fuel dispensing points and in their 14 service trucks. Now, the client is able to meter and record all deliveries, track every fuel dispense, and record all transfers to service trucks. Thanks to greatly improved visibility, they have reduced the gap between fuel ordered and fuel consumed to less than 1%. In the first year of using the system, they saved 3 million litres of fuel. Staff can also now make more informed decisions about crucial aspects of site performance, including determining which vehicles to buy based on their fuel burn rate performance.
When one of the world’s largest nickel mines wanted a way to improve their monitoring and control of fuel dispenses for their light vehicles, they approached FluidIntel. The client already had over 8,000 Cardax (Gallagher) access cards in place, and wanted a way to utilise this existing system so as to save precious time and money. We worked with the client to customise AdaptIQ so that it could easily and automatically import the existing information from the clients’ existing fuel user RFID cards. As a result, all of the client’s Cardax card users were automatically verified and imported into AdaptIQ without any human intervention, and on an ongoing basis, any changes to users in Cardax system are propagated into AdaptIQ every ten minutes. The client has been able to save on their labour costs and has significantly reduced their data entry errors. Their light vehicle refuel volumes have also dropped due to dual authorisation, even though staff numbers have increased.
When one of our clients was made aware – through a standard service – that the oil in one of their service trucks had been contaminated, it could very quickly have become a much bigger problem. This vehicle provided oil to several other vehicles and equipment, so it was essential they determined how far the contamination had spread. Fortunately, thanks to AdaptFMS, the client was able to easily identify which vehicles or equipment in the fleet were potentially contaminated, considerably narrowing the number of vehicles requiring inspection. They simply gave these vehicles an oil drain and replenished them with new oil. The client was able to avoid sending out dozens of samples for testing – an overall saving of approximately $44,000. They were also able to maintain equipment warranties across their fleet.
While the Australian Tax Office provides a rebate for fuel used on mine sites, claiming this rebate is a complex process and requires mine operators to collect and store considerable data regarding the type and quantity of fuel acquired, the date acquired, and how it was used. For one of our clients, AdaptFMS has made this process far easier and more effective. The system meters and records on-site fuel transactions, as well as off-site fuel use identified by itemising consumption to each fuel-consuming asset. The system is also future-proofed if the legislation or rebate levels change, as AdaptFMS can give each piece of equipment a different, user-settable rebate level.
The client now has complete Australian Tax Office auditable records for their fuel purchase, use and consumption. This eliminates the risk of inaccurate claims, and they can file their quarterly rebate claims more easily with our customised fuel tax rebate reporting function.
A large mine site receives 1,500 fuel truck deliveries per year, and requires at least two on-site, full time fuel managers to check the fuel inventory as it arrives, and to manually order supplies. One of our clients approached us wanting a way to streamline this process. We designed and installed tank gauging and associated equipment to provide 24/7, on-line remote tank monitoring with stock on hand and stock trend reports, which are now automatically emailed every three hours direct to the site’s fuel vendor, who manages their re-supply without site staff involvement. We also eliminated the need for the client’s staff to maintain time-consuming spreadsheets, and helped provide a safer work environment by removing the need for staff to perform manual dips and checks. The system has been so successful that the client is now applying it to their oil (lubricant) management.
Unauthorised fuel use can weigh very heavily on any mine site’s bottom line. When one of our clients became concerned that their contractors were using more fuel than was approved, they approached FluidIntel to develop a solution. We developed a special feature for our existing AdaptFMS, which enables the client to limit the amount of fuel each vehicle can take per shift, per day, per week, or per month. This means vehicles can only be filled up once per shift (or other nominated period), which stops drivers taking additional fuel off site, or taking fuel for personal use. We also installed ID tags that identify and authorise contractors to access fuel: no ID tag, no fuel. The client reported fuel savings in the first year of $527,000, from a total fuel spend of $100 million. This includes savings generated through the limit dispense feature, safe fill levels, and other fuel authorisation technology.
Most mine sites dispense some fuel and lubricants from mobile Service Trucks (Fuel Carts) directly into mobile equipment. Analysis of dispensing output from a fleet of service tucks fitted with AdaptMacs showed that productivity across operators varied significantly, with the better operators dispensing up to 71% more per shift compared to the poorer performing operators. By continuously monitoring service truck operator shift productivity, benchmarking operators and providing feedback and training on how to improve outcomes, productivity has improved by over 23%. This has allowed the site to remove one Service Truck from operation saving over two million dollars per annum.