1) The document summarizes how Zonar telematics systems helped a general contractor, Goodfellow Brothers, improve safety and efficiency by reducing fuel costs and idling, streamlining vehicle inspections, prioritizing maintenance issues, and tracking high-value equipment.
2) Key benefits included annual fuel savings of $54,000 from reduced idling, greater maintenance shop efficiencies from prioritized issues, and improved transparency for customers and regulators through detailed reports.
3) The contractor used Zonar solutions across its 1,200 vehicle fleet serving projects across multiple US states and Hawaiian islands.
1. I interviewed the visual inspection analyst and equipment department manager of
Goodfellow Brothers Inc. General Contractor for a Zonar Systems testimonial.
(www.zonarsystems.com). Following the interview, I discussed with the client the various
ways in which Zonar had helped the general contractor in reducing fuel costs by
reducing excessive idling, establishing a reliable and complete vehicle and inspection
regimen resulting in complete and consistent inspection reports, realizing significant
improvements in the efficiency of the maintenance shop, instituting an effective way to
prioritize maintenance issues resulting in the reduction and elimination of equipment
breakdowns, reducing excessive weekend vehicle usage, and setting up high-value
equipment with tracking devices to make theft recovery easier.
On my recommendation, I wrote a main story and three sidebar stories, which offered the
most opportunities to pitch and place the Goodfellow Bros. testimonial in multiple
construction and fleet trade publications.
This resulted in magazine articles in the following eight trade magazines – Business
Fleet, Fleet Maintenance, Heavy Equipment Guide, Modern Work Truck Solutions,
Sustainable Construction, Utility Fleet Professional and Utility Products. And in stories
posted on six corresponding trade web sites – ForConstructionpros.com, MWSmag.com,
truckfleetmanagement.com, utilityfleetprofessional.com, vehicleservicepros.com, and
worktruckonline.com.
Zonar Improves Safety and Delivers Shop
and Fleet Efficiencies for General Contractor
GoodfellowBrothers Earns $54,000 inAnnual Fuel CostSavings
Senior managers at Goodfellow Brothers Inc. General Contractor face a geographical
challenge like few others in their profession. They must coordinate the activities of fleet
operations and several maintenance shops separated by more than 2,500 miles of Pacific
Ocean and spread out over a vast area that includes three time zones.
The fourth-generation family-owned company operates a fleet of 1,200 vehicles and
earth-moving equipment on several project sites on all five of the Hawaiian islands, and
in Oregon and Washington. The company works on a variety of different construction
projects including airport runways and taxiways, bridges and other road transportation
projects, marinas and site preparation for housing and business developments.
Coordinating the maintenance and operations of that many pieces of equipment over the
company’s huge territory is the responsibility of a small group of Goodfellow Brothers
managers at the company’s headquarters in Wenatchee, Wash. The group has always
successfully managed the fleet operations, maintaining safety awareness and keeping on
top of equipment and truck repairs, said Richard Kornmann, visual inspection analyst for
Goodfellow Brothers.
2. “Still, we knew we could do better,” Kornmann said. “We suspected that we had
problems with excessive weekend vehicle usage and idling; and with illegible,
incomplete and inconsistent vehicle inspection reports. We also had drivers speeding to
and from work sites and through them to get to work, to stay on schedule or to finish their
assignments.
“Without some way of measuring what was happening, we really had no idea about the
extent of these issues,” he added. “And we certainly couldn’t hold our employees
accountable for things we weren’t tracking.”
Starting in 2010, Goodfellow Brothers’ managers turned to Zonar for answers. With
Zonar’s help, Gooodfellow Brothers implemented a four-phased telematics project to
improve the safety and efficiency of the company’s fleet operations.
The first phase involved equipping the company’s fleet of about 450 pickup trucks with
Zonar’s telematics system and then monitoring usage through the Zonar Ground Traffic
Control web application. During the second phase, which started a year later, the
company outfitted its construction vehicles — including dump trucks and about 650
earth-moving units, with the Zonar telematics system and the Zonar Electronic Vehicle
Inspection Reporting (EVIR) system. The third phase involved monitoring the fuel usage
and emissions of its rock crushers. And during the fourth phase, the company provided
suppliers Zonar’s portable telematics devices to get a more complete view of its work
sites.
“During the first phase, we monitored how pickup trucks were driven and operated, then
we used the information in a training program to counsel drivers,” Kornmann said.
Goodfellow Brothers Realizes $54,000 Annual Savings in Fuel Costs
Within a year, Goodfellow Brothers achieved an immediate drop in weekend vehicle
usage, speeding and idling. By cutting the incidences of idling in half, the company
realized an annual savings of about $54,000 in fuel costs. Pickup drivers no longer left
their engines running while stopped at job sites.
“In the reports generated by Zonar, the amount of time each truck spent idling surprised
us all, particularly the drivers,” Kornmann said. “Before we implemented Zonar, it wasn’t
uncommon for us to see our trucks and equipment burn as much as $600 worth of fuel
each week just idling.
“After implementing Zonar and providing drivers counseling on how to reduce their
idling, we saw the amount of fuel burned due to idling reduce to $160 to $180 per week,”
he said. “Now it’s rare if we break $100 per week in fuel costs due to idling, and that’s
usually on account of traffic. And incidences of speeding are practically nil.”
3. While the reduction in annual fuel expenses more than paid for the cost of implementing
Zonar, Goodfellow Brothers managers say success with the telematics project’s second
phase is what really paid off for the company.
During the second phase, Goodfellow Brothers established its two-tier program that
indicates the severity and importance of issues discovered by vehicle and equipment
operators during their pre- and post-trip inspections. The alerts also prioritize issues
reported by onboard equipment and vehicle sensors and computers, such as engine
performance.
Goodfellow Brothers Experiences Greater Maintenance Shop Efficiencies
“Any issue or problem that could inflict injury or endanger the lives of our employees or
others, or lead to further damage to a machine is considered a red alert,” said John Stump,
equipment department manager for Goodfellow Brothers. “Yellow alerts are for issues
that should be addressed, but don’t require immediate attention.
“For example, if the operator reports that the back-up alarm isn’t working, that would be
considered a red alert,” Stump said. “Any equipment with a non-working back-up alarm
would be taken out of service until it’s fixed.”
In many cases, particular problems like non-working back-up alarms are already preset as
red-alert issues on Zonar’s EVIR, Stump added. But the inspection application allows
equipment or vehicle operators to reclassify yellow-alert issues with a higher red-alert
priority when they deem the situation requires it.
The alerts are immediately communicated back to the maintenance shops. Maintenance
technicians can then schedule the repair when the vehicle returns to the shop or assign a
remote service repair truck if the vehicle or equipment can’t be driven or moved to the
shop. Red alerts are also communicated to dispatchers and the company’s headquarters in
Wenatchee, notifying senior company managers. The senior managers follow up a few
days later to see if the local maintenance shop has completed the repair or needs more
resources.
Stump said this two-tier alert system, utilizing Zonar’s EVIR and telematics systems,
helped his company significantly increase the amount of scheduled work the company’s
seven maintenance shops can complete in a week. By using Zonar’s equipment, drivers
identify potential maintenance issues so they can be addressed long before they cause
equipment breakdowns, and become unscheduled work, which can slow or even stop
progress at job sites, he added.
“We’ve been able to achieve better than the industry standard of 65 percent efficiency at
our maintenance shop in Maui and 55 to 60 percent efficiency at our other locations with
the information we get from Zonar,” Stump said. Shop efficiency is measured in how
much scheduled work gets done each week. So 65 percent efficiency means the shop has
completed 65 percent of its scheduled work.
4. Goodfellow Brothers Plugs into More Savings with Crushing Fuel Reports
For the telematics program’s third phase, Goodfellow Brothers added Zonar RFID tags to
its crushing equipment. When the crushing equipment gets refueled, employees can scan
the RFID tags and report the amount of fuel they put into the machines and the number of
hours the machines have run. This allows managers to closely monitor fuel usage and
emissions. Weight scales were also added to the crushing belts to measure tons per hour.
And for the program’s fourth phase, Goodfellow Brothers provided trucking companies
that haul equipment and supplies to and from its work sites with Zonar telematics units
that plug into a cigarette lighter. These plug-and-play devices offer Goodfellow Brothers
a more accurate look into what’s happening at the job sites when supplies and equipment
are delivered. Stump said managers can use the suppliers’ arrival and unloading times to
gain additional job site efficiencies.
“We can see if suppliers and vendors are having to wait to unload their equipment or
supplies,” he said. “That can indicate to us that we have some scheduling problems or
other delays on the job site that need to be addressed.”
Goodfellow Brothers management provides customers and regulatory agencies access to
the detailed reports that Zonar telematics equipment offers. So customers and regulatory
agencies know when crushing equipment is operated; when supplies and equipment are
delivered; when trucks and other equipment are inspected; and if there were any issues
found, how quickly those problems were fixed, Kornmann said.
“We’ve found that regulators and customers appreciate the level of transparency this
provides them,” he added.
Goodfellow Brothers managers also appreciate the operational savings their company has
enjoyed with Zonar.
“But it’s more than just those operational efficiencies,” Stump said. “The unique driver
inspection capabilities Zonar offers us to focus and improve on equipment safety,
coupled with the transparency we can offer our customers and to regulatory agencies,
demonstrates that we don’t just talk about safety, we live it in everything we do. It’s why
Goodfellow Brothers has become a subcontractor of choice for companies like RES
Americas Construction Inc.”
Sidebar 1
Zonar Results in Safer Operations through Automated Inspection Reports
When it comes time for Goodfellow Brothers operators to identify vehicle and equipment
defects that can lead to potential safety issues or breakdowns, the Zonar EVIR (electronic
vehicle inspection report) can help them stay in the zone.
5. Radio-frequency identification (RFID) tags are placed on equipment in critical inspection
“zones.” These weather-tough tags contain information about their location on the unit,
the components to be inspected and the identity of the vehicle or piece of equipment.
Using Zonar’s EVIR inspection tool and Zonar’s 2020 tablet, Goodfellow Brothers
equipment and vehicle operators conduct their inspections by placing the reader within
inches of each tag and indicating the condition of the components within the zone with
one-handed, push-button responses. When a defect is discovered, the operator selects a
description from a pre-defined list and indicates if the defect warrants a yellow or red
alert unless the condition is preset as a red alert.
When the inspection is complete, operators place the mobile unit into the mount,
typically located inside the cab. Zonar’s telematics platform gathers that electronic trip
inspection data and transmits that data wirelessly to Zonar’s web-based Ground Traffic
Control data management application. Meanwhile, the telematics platform also transmits
in real time diagnostic data whenever the equipment is in operation. Zonar integrates the
data from the EVIR and telematics system into Goodfellow Brothers’ fleet maintenance
system. This integration allows service requests to be automatically generated and
transmitted through the company’s portal to the regional office maintenance shops.
Maintenance technicians at Goodfellow’s seven maintenance facilities at the regional
offices in Maple Valley, Wash., and Portland, Ore., and on all five of the Hawaiian
islands, provide maintenance support for the company’s fleet of 1,200 pieces of
equipment. The technicians work in the shops and occasionally travel out into the field to
do on-site maintenance on the company’s fleet using service trucks. The fleet includes
cars, pick-up trucks, larger on-road trucks such as haul and dump trucks, tractors to pull
flatbed trailers for hauling off-road equipment and 650 earth-moving units such as
bulldozers, motor graders and excavators. The Wenatchee headquarters acts as a central
hub for the company – offering technicians and their supervisors management assistance.
Once repairs are performed and marked completed, they are automatically uploaded to
Zonar’s web-based Ground Traffic Control data management application, indicating that
the vehicle is in full compliance for operation. Because the data management application
is web-based, company dispatchers and managers know when the equipment or trucks are
ready to return to service.
“Equipment and vehicle operators are required to do their daily inspections and they are
charged with the responsibility for making sure their equipment is safe and in good
working order,” said Richard Kornmann, visual inspection analyst for Goodfellow
Brothers. “Any defects must be reported and Zonar gives our employees the tools they
need to do that job.
Sidebar 2
Zonar Helps Keep$500 Million Wind Farm Project Site Moving
6. On a wind-swept ridge overlooking the Tucannon River, a tributary of the Snake River
fed by snowpack on the distant Blue Mountains to the east, RES Americas Construction
Inc. is leading the construction of a $500 million wind farm at a 20,000-acre site near
Dayton, Wash. When completed, the Tucannon River Wind Farm’s 116 wind turbines
will have a total generating capacity of 267 megawatts of electricity, making it Portland
General Electric’s second largest renewable energy project. The wind farm is expected to
produce an average of around 101 megawatts, enough to power the homes of about
84,000 residential customers.
Goodfellow Brothers is building 40 miles of new road for the project and preparing each
of the sites for the wind towers and turbines. When completed, each wind turbine tower
will stand 160 feet from the ground to the turbine motor, with three 110-foot blades.
Shipped from Europe, the massive parts of the wind towers and turbines arrive by boat in
three sections and are loaded onto a train and shipped to Eastern Washington, where they
are loaded onto trucks to be delivered the last hundred or so miles to the wind farm.
“Everything must be coordinated,” said Richard Kornmann, visual inspection analyst for
Goodfellow Brothers. “So, the road work and site preparation must all be completed on
several tower locations before the erection crews arrive.”
Kornmann said when the parts start to arrive, installation of the towers must be done by
three separate teams with different equipment. Each team is responsible for different
sections. The first team installs the tower base. The second team installs the turbine and
the third team installs the blades.
“Once the erection crews arrive on site, site preparation at each tower pad must be
completed in a timely fashion so that the crews can continue their work and keep to their
schedule,” said John Stump, equipment department manager for Goodfellow Brothers
“The cranes used in the installation are very expensive to operate. Any delays on our part
would result in hefty penalties against our company and we would lose a lot of money.
There’s no room for error.”
Kornmann said Zonar equipment provides Goodfellow managers real-time information
that they can use to monitor progress on the site preparations and to deal with any
equipment issues that could potentially delay the entire project. And since managers can
generate detailed reports that include engine hours plus vehicle speed, location and
condition, they can provide RES Americas more detailed and accurate reports.
“RES Americas places a great deal of emphasis on safety,” Kornmann said. “The
maximum speed limit for all vehicles on the project site is 20 mph. There are no
exceptions. And we must provide proof to RES Americas that we strictly enforce that
speed limit at all times.
“Since the distance from one end of the wind farm project to the other is more than 15
miles, it can take anywhere from 45 minutes to an hour to travel from one tower pad to
7. another,” he added. “That places even greater time restrictions on our on-site crew of 35
employees. If they run late, they can’t speed through the project to get to the next tower
pad.”
“Having access to engine hours also helps us in monitoring rental units and PTO
operations on trucks so that the company’s accountants can determine and claim any state
and federal fuel tax reimbursements,” Kornmann said.
Equipment Improvements Cut Installation Time in Half, Improve Connectivity
Improvements recently made by Zonar have contributed to a vast improvement in
connectivity, particularly in remote rural areas like the Tucannon River in southeastern
Washington, Kornmann said.
“In these rural areas, we’ve seen a 80 to 90 percent improvement in reception,” he said.
“This means that I have many fewer gaps in vehicle and vehicle inspection data.”
Recently, Goodfellow Brothers began upgrading to the Zonar V3R telematics platform,
which features a newer generation of wireless technology than the company’s previous
units. And Goodfellow has been installing newer wire harnesses from Zonar in its
vehicles, which cuts the installation time of the telematics system in half from more than
2 hours to less than an hour. Since the V3R and the new wiring harnesses can connect to
the on-board diagnostic (OBD-II) ports of most vehicles, Goodfellow Brothers managers
could have access to an even greater treasure trove of data particularly from its Ford
pickup trucks.
“There’s no question that Zonar helps us save money through greater operating
efficiencies,” said John Stump, equipment department manager for Goodfellow Brothers
“But what’s been really important to us is how Zonar has helped us to more closely
monitor our vehicles and equipment so that we can remain the contractor of choice for
our customers and our employees because we maintain a safe and efficient work
environment.”
Sidebar 3
Zonar Asset Tracking Device Catches Thieves Red-Handed with Stolen Truck
In 2012, maintenance technicians at the Goodfellow Brothers maintenance shop on the
island of Oahu discovered the company’s $65,000 service truck was missing one
morning.
Because the labor truck was equipped with the Zonar ZTrak asset tracking device, Zonar
located the service truck 50 minutes before the signal went dead, said John Stump.
equipment department manager for Goodfellow Brothers. So, when the maintenance crew
reported the stolen service truck to the Oahu Police Department, they were able to tell the
Oahu Police exactly where the truck was parked.
8. Using those coordinates, the police discovered the truck body in a residential area under a
blue tarp after it had been stripped of its tools. The police apprehended the suspects red-
handed, recovered the truck and shut down an active theft ring, Stump said.
“We now have Ztrak equipped on all of our arrow boards (lighted traffic reader boards),”
said John Stump, equipment department manager for Goodfellow Brothers “That’s
because they have solar panels and are prime targets for people who grow marijuana
illegally. We also have the Ztrak devices on our ATVs and any other equipment that
could be stolen.”