abb consulting and full service-the road to efficiency and reliability-april2013
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The road to Efficiency and ReliabilitySammy Saba – Marketing and Sales Manager ABB Global Consulting – April 2013
ABB Global Consulting and Full Service
ABB Global ConsultingOur portfolio 1/2
Portfolio Activities Definition / Scope
Efficiency
CMMS
Implementation and customization of CMMS System (SAP PM,INFOR EAM, MAXIMO, ABB…..)Design and Implementations of communication interface between ERP and CMMS System
Warehouse Management Optimization
Analysis and optimization of Warehouse management (Safety Stocks, Rotation Index, Min/Max Stock,..)Coding and Standardization of Spare Parts
Energy Efficiency Improvement
Energy Efficiency auditUNI EN 50001 Implementation Feasibility Study (ROI & KPI’s Identification)Improvement action and Energy Efficiency Credit Management (TEE)
Engineering Activities
Revamping Study of Electrical, Mechanical and Thermal SystemsEquipment and Process Assessment (Electrical, Mechanical and Thermal)Machinery re-certificationOperational Engineering support
Reliability Reliability EngineeringRAM’s Analysis (reliability, availability and maintainability)RCM – RCA – RBI AnalysisImprovement actions
ABB Global ConsultingOur portfolio 2/2
Portfolio Activities Definition / Scope
Safety, Quality and
Training
Safety & EnvironmentalEnvironmental Management System (ISO 14001)Operational Health and Safety Management System (OHSAS 18000)SIL - Safety Integrity LevelRisk Assessment
Validation Process and Equipment
GxP Impact assessment (Good Laboratory / Manufacturing Practice)Computer System Validation (GAMP 4 - Good Automated Manufacturing Practice)DQ, IQ, OQ, PQ (Design, Installation, Operational & Performance Qualification)Metrological laboratory & calibrations
Training and Coaching
Internal and External training related to: Reliability Centered Maintenance – Asset Criticality Analysis – OEE Analysis and Monitoring - Preventive Maintenance Optimization – Condition Based Maintenance - Planning & Scheduling –- Autonomous Maintenance and 5S - Six Sigma methodology - Energy Efficiency Concept and Implementation - Warehouse management and optimization - CMMS Computerized Maintenance Management System
ABB Full ServiceOur portfolio
Portfolio Activities Definition / Scope
Perfomance Based
Agreements
Operation & MaintenanceOperation & Maintenance is a long-term performance based on partnership agreements on Lump Sum and KPI for all Maintenance and Operation activities
Full Service Full Service contract is a long-term performance based on partnership agreements based on Lump Sum and KPI for all Maintenance activities
Equipment Performance Management
Full service o Global Service of Maintenance related to the specifics Equipment (e.g.: Motor, Instruments.) based on Lump Sum and KPI
Asset Management for Fuel Retail Stations
Global management of the activities directly and indirectly linked to the Maintenance of fuel retail networks and of the relevant services
Maintenance Management &
Supervision
Turn-Around Maintenance (TAM)
TAM (Turn-Around Maintenance) consists in all the cyclical and also extraordinary strategic maintenance activities planned and managed during the stop planned production.
Maintenance Management & Supervision
Maintenance Management & Supervision consists in the leading Maintenance workforce and supervisor of the work
Maintenance & Productivity
Implementation and EEI
Maintenance & Productivity Implementation
Improve OEE, reduce Maintenance spend, optimize resources and stock inventory, minimize risk, RCA, FMECA analysis, CMMS Implementation and management
Energy Efficiency Improvement
Feasibility Study on electrical and thermodynamic equipment and implementation projects with performance based contract (EPC)
© ABB Group April 10, 2023 | Slide 5
ABB Efficiency and Reliability The approach
Energy Efficiency
Safety & Environment
Spare Parts Optimization
Plant Reliability
Energy Saving Safety & environmentCapex ReductionDown Time Reduction
Costs optimization
SW for Maintenance & Reliability Design: EMDS (Engineering Maintenance Design System), FMEA+CA (Failure mode
Effects & Criticality Analysis); SW for Maintenance Management:
CMMS (Enterprise Asset Management)
SW for Spare Parts Optimization: ISPO
(Inventory Spare Parts Optimization), CODE
MAKER (coding for spare parts)
SW for Energy Efficiency Implementation: E2P
(Energy Efficiency Platform) E2AM (Energy Efficiency
Asset Management)cpmPlus (Energy
Management System)
Safety & environmental services, Process
Validation, Remediation,
Decommissioning, Technical Training Path
Training
© ABB Group April 10, 2023 | Slide 6
ABB Efficiency and Reliability Energy Efficiency
ABB’s portfolio includes:
Analysis and energy balance of the vectors
Measurement/analysis of historical trends and identification of the optimal consumption profile
Thermal balance verification for systems and subsystems
Rationalization and optimization of processes and energy systems
Identification of improvement areas and implementation of technical solutions for energy efficiency and for use of renewable energy sources
Turn key solutions for energy efficiency and verification of reached results
Implementation of EnMS – ISO 50001:2011 system
With the aim to reach the following results:
Energy consumption/costs reduction, CO2 reduction
Energy waste reduction
Optimization of overall plant energy consumption
Energy supply contract optimization
© ABB Group April 2012 | Slide 7
Verification
FeasibilityStudyReport
ImprovementMaster Plan
Improvement Opportunity
Sheets
Feasibility Study
UtilitiesUtilities
Analysis of Equipments
Check-upReport
Check-UpPHASE
AREA
OUTPUT
Realization of
Solution
Activities Supervision
Realization of Solution
Return of Investment
In the absence of data, ABB offers a measurement service for any vector personalized for the real needs of the Customer.
(*)
Utilities
PotentialOpportunity
Portfolio
Flash Audit
Report
Flash Audit
Analysis of the Areas
Energy Mapping (Sankey diagram)
Trendsanalysis (*)
Energy Mapping e
Measurement
Edifici UtilitiesBuilding UtilitiesUtilities
Prod.Area
Organiz.
Detailed
Design
Design and technical
specification
ABB global approach to Energy EfficiencyA complete process from analysis to implementation(EN 15900:2010)
Description of the energy scenario achieved
Gap identification and analysis
Measure andVerificationof Results
ImplementationEnergy AuditPreliminary
Analysis
Building UtilitiesUtilities
Prod.Area
Organiz.
Building UtilitiesUtilities
Prod.Area
Organiz.
Building UtilitiesUtilities
Prod.Area
Organiz.
Building UtilitiesUtilities
Prod.Area
Organiz.
Building UtilitiesUtilities
Prod.Area
Organiz.
Building UtilitiesUtilities
Prod.Area
Organiz.
Carried out by the CustomerWith support of ABB specialists
Carried out by ABB specialists
Carried out by the Customerin complete independence
© ABB Group April 10, 2023 | Slide 8
ABB Efficiency and Reliability Plant Reliability
ABB supports Customers offering a wide range of maintenance solutions, that
can be sized on Customer needs: from consultancy services, dedicated to
specific areas, to long-term performance based agreements for outsourcing
maintenance.
Main target of these activities is the plant reliability and efficiency
improvement, the increase of plant life cycle and the maintenance costs
optimization. The proposed activities are the folowing:
Operation & Maintenance
Full Service
Equipment performance management
Asset management for fuel retail stations
Turn-around maintenance (TAM)
CMMS implementation & customization
Reliability engineering
© ABB Group April 10, 2023 | Slide 9
ABB Efficiency and Reliability Spare Parts Optimization
ABB helps its Customers in optimizing the warehouse management by
standardizing the spare parts coding, categorizing spare parts basing on their
criticality and setting new indicators with the aim to reduce fixed assets and to
improve the spare parts procurement process. ABB’s offer is composed by the
following activities:
Spare parts classification and standardization
Vendor rating
Definition and monitoring of stock turnover index
Definition and monitoring of reorder points and safety stocks
CONTINUOUSMPROVEMENT
© ABB Group April 10, 2023 | Slide 10
ABB Efficiency and Reliability Material Management and Optimization
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Performances Assessment
Warehouse Management
Warehouse Continuous Improvement Program
Roadmap – ABB Material Management and Optimization Model
Pre-Analysis
Pre – Analysis
• Warehouse organization
• ERP / CMMS systems
• Inventory data (last 3-years) analysis: goods receipts, purchase orders, consumption….
• Failure Equipment records
• Spare parts and Equipment relationships
ISPO – Inventory Spare Parts Optimization
Criticality Analysis
DESIGN & OPTIMIZATION
Performances Assessment
• Suppliers and Catalog analysis
• Spares and Equipment relationships analysis
• Spare Codification Design
• Materials Management System Data collection (store investment, utilization db, inventory turnover,..)
• Inventory Data collection: Material List Lead Time Price Consumption Plant Downtime cost
• Material Models Design
Criticality analysis
• Categories spares codification and attribution
• Modeling of Cost of Stock Out of Material (by FMECA, process and functionality, costs, safety & quality)
• Critical Classes of Materials Analysis (Module A–B)
• Critical Spare Parts Analysis (Module C–D)
Optimization
• Critical Spare Identification
• Inventory Indexes Calculation
• Safety Stock definition by Classes / Spare (Module B – D, min/max, Q, EOQ,SS)
• Database updating
• Reporting design
Optimization
MANAGEMENT
Material Management
• Trainings and Coaching of Warehouse Management
• Warehouse automations (RF- RFID, standard barcode, QR..)
• Spare Part Tracking
• Warehouse Management: Material handling, Purchasing, virtual storage….
• Supply chain management (web-based)
• Spare parts standardization and codification
• Stock levels Monitoring (min / max, Q, EOQ,Ss)
WCI Program
• Web Hosting Service for stock analysis
• Safety Stock management (min/max, Q, EOQ, SS)
• Inventory yearly analysis & revisions
• Cost of stock out analysis and remediation
• FMECA analysis
• Spare criticality redefinitions
• Inventory Assessment
WMA WCI
© ABB Group April 10, 2023 | Slide 11
ABB Efficiency and Reliability Safety & Environment
Quality, safety and environmental care are very important values for ABB. ABB
consultancy services in these fields include:
Implementation of ISO 14001 environment management system
Implementation of OHSAS 18000 safety management system
SIL (Safety Integrity Level) analysis
Risk assessment for safety and environment
Remediation and decommisssioning services, such as:
Environmental risk assessment
Underground tank remediation
Industrial remediation (preventive and emergency)
Decommissioning
Service for validation and calibration, such as: GxP impact assessment
Computerized system validation
DQ, IQ, OQ, PQ
Metrological laboratory analysis and calibration
© ABB Group April 10, 2023 | Slide 12
ABB Efficiency and Reliability Training
For each operational area, ABB provides an high quality complete technical
training, to be choosen inside the wide training catalogue: ABB offers the
possibility to create, for each technical profile, a highly professional training
path.
These are the training areas:
Reliability
Planning and scheduling
Preventive and predictive maintenance
Assets criticality and process mapping
Warehouse management
Maintenance methodologies
5S
Six Sigma
CMMS
Energy efficiency
© ABB Group April 10, 2023 | Slide 13
ABB Efficiency and Reliability The road to efficiency and reliability - Assessment
Energy Efficiency
Safety & Environment
Spare Parts Optimization
Plant Reliability
Check Up/ Opportunity
Identification/ Master Plan
Training
Feasibility Study
Warehouse Assessment
Safety & Environment Assessment
Energy Efficiency Improvement
Performance Based Agreements
Maintenence Mgmt & Supervision
CMMS & Engineering Activities
Reliability Engineering
Warehouse mgmt & Optimization
Process Validation
Remediation & Decommissioning
© ABB GroupApril 10, 2023 | Slide 14
ABB Efficiency and ReliabilityRoadmap Overview
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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from Design to Performance Based Agreements……….
…..in order to achieve:
• productivity increase;• maintenance costs reduction;• energy efficiency;• Quality and HSE improvements;
and much more…..
© ABB GroupApril 10, 2023 | Slide 15
ABB Efficiency and ReliabilityMutual Commitment
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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MPI (Maintenance & Productivity Implementation) + EEI
Agreement
• Assessment
and
Project definition
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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ABB Efficiency and ReliabilityDesign
MPI (Maintenance & Productivity Implementation) + EEI
Module 1
• As is analysis
• Strategy definition
• Measurement system definition and implementat.
• Reliability analysis and Implementat.
© ABB GroupApril 10, 2023 | Slide 17
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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ABB Efficiency and ReliabilityImplementation
MPI (Maintenance & Productivity Implementation) + EEI
Module 2• Computerized Maintenance Management System Impl.
Module 3
Module 4
© ABB GroupApril 10, 2023 | Slide 18
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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ABB Efficiency and ReliabilityImplementation
MPI (Maintenance & Productivity Implementation) + EEI
Module 5
Module 6
© ABB GroupApril 10, 2023 | Slide 19
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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ABB Efficiency and ReliabilityImplementation
MPI (Maintenance & Productivity Implementation) + EEI
Module 7
© ABB GroupApril 10, 2023 | Slide 20
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM /AMF/FS/O&M
Roadmap - Efficiency and Reliability
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ABB Efficiency and ReliabilityFollow-up – Coaching and training on the job
MPI (Maintenance & Productivity Implementation) + EEI
Module 8
© ABB GroupApril 10, 2023 | Slide 21
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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ABB Efficiency and ReliabilityMaintenance Management & Supervision
Work Supervision
Maintenance Management
Maintenance Management & Supervision consists in leading Maintenance workforceand supervising the work.
These modules include the following activities:planning & scheduling, works supervision and management, Maintenance Engineering analysis, improvement design, performance monitoring, HSE and Quality management.
MPI (Maintenance & Productivity Implementation) + EEI
Turn-Around Maintenance
Turn-Around Maintenance consists in all the cyclical and also extraordinary strategic maintenance activities planned and managed during the stop planned production.
© ABB GroupApril 10, 2023 | Slide 22
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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ABB Efficiency and ReliabilityPerformance Based Agreements
EPM
Operation & Maintenance Contract is a long-term performance based partnership agreement (Lump Sum price and KPIs) for all Operation and Maintenance activities (specifically for Power and Utility plants and industries)
EPM Equipment Performance Management is specific Global Service of Maintenance related to specific Categories of Equipment (e.g.: cogenerations, motors, instruments, drives, etc...) The Contract is based on Lump Sum price and KPIs.
MPI (Maintenance & Productivity Implementation) + EEI
Full ServiceABB Full Service® Contract is a long-term performance based partnership agreement (Lump Sum price and KPIs) for all Maintenance activities (Industries: Pulp & Paper, Metals, Minerals & Mining, Oil & Gas, Petrochemical, Manufacturing, Chemical, Crane & Harbor, etc…)
AMFAsset Management for Fuel Retail Stations is involved in global management of the activities directly and indirectly linked to the Maintenance of fuel retail networks and of the relevant services
Operation & Maintenance
© ABB GroupApril 10, 2023 | Slide 23
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Design Implementation Follow-upMaintenance Management
& Supervision
Performance Based
Agreements
MMS / TAM EPM/AMF/FS/O&M
Roadmap - Efficiency and Reliability
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ABB Efficiency and ReliabilitySoftware and Application Tools
MPI (Maintenance & Productivity Implementation) + EEI
Software for Maintenance and Reliability Design:
EMDS(Engineering Maintenance
Design System)
FMEA + CA(Failure Mode Effects and
Criticality Analysis)
Software for Spare Parts
Optimization:
ISPO(Inventory Spare Parts
Optimization)
CODE MAKER(Coding of spare parts)
Software for Energy Efficiency
Implementation:
E2P (Energy Efficiency
Platform)
E2AM (Energy Efficiency Asset
Management)
Software for Maintenance Management:
CMMS(Enterprise Asset
Management)
Software for Productivity
ManagementCPM+
(Real-Time Production Intelligence)
OEE Rec(Overall Equipment
Effectiveness Recorder)
© ABB GroupApril 10, 2023 | Slide 24
ABB Efficiency and ReliabilityWeb-based platform
Software for Maintenance and Reliability Design:
EMDS(Engineering Maintenance
Design System)
FMEA + CA(Failure Mode Effects and Criticality
Analysis)
Software for Spare Parts
Optimization:
ISPO(Inventory Spare Parts
Optimization)
CODE MAKER
(Coding of spare parts)
Software for Energy Efficiency
Implementation:
E2P (Energy Efficiency
Platform)
E2AM (Energy Efficiency Asset
Management)
Software for Maintenance Management:
CMMS(Enterprise Asset
Management)
eSOMS(Electronic shift Operat. Maint.
System)
Software for Productivity
Management
CPM+(Real-Time Production
Intelligence)
OEE Rec(Overall Equipment
Effectiveness Recorder)
ABB H.Q.
EMDS FMEA CA ISPO OEE
REC
CODE
MAKER
E2P E2AM
(CPM+)
CMMS
CUSTOMERInternet
eSOMS
ABB Reliability & Maintainability platform ABB Energy Efficiency platform
ABB O&M platform
© ABB GroupApril 10, 2023 | Slide 25
Key relationshipsABB Reliability & Maintainability platform
FOR FURTHER QUESTIONS
PLEASE CONTACT:
e-mail: [email protected]
e-mail: [email protected]
Contacts
© ABB Group July 2nd 2012| Slide 26