ABB Consulting and Full Service-The road to efficiency and reliability-april2013

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


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


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


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 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.


Prod.Area

Organiz.


Prod.Area

Organiz.


Prod.Area

Organiz.


Prod.Area

Organiz.


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 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 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 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 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 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 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


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 Efficiency and ReliabilityMutual Commitment

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& Supervision

Performance Based

Agreements

MMS / TAM EPM/AMF/FS/O&M


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MPI (Maintenance & Productivity Implementation) + EEI

Agreement

• Assessment

and

Project definition


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& Supervision

Performance Based

Agreements



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ABB Efficiency and ReliabilityDesign


Module 1

• As is analysis

• Strategy definition

• Measurement system definition and implementat.

• Reliability analysis and Implementat.


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& Supervision

Performance Based

Agreements



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ABB Efficiency and ReliabilityImplementation


Module 2• Computerized Maintenance Management System Impl.

Module 3

Module 4


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& Supervision

Performance Based

Agreements



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Module 5

Module 6


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& Supervision

Performance Based

Agreements



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Module 7


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& Supervision

Performance Based

Agreements

MMS / TAM EPM /AMF/FS/O&M


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ABB Efficiency and ReliabilityFollow-up – Coaching and training on the job


Module 8


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& Supervision

Performance Based

Agreements



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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.


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.


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& Supervision

Performance Based

Agreements



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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.


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


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& Supervision

Performance Based

Agreements



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ABB Efficiency and ReliabilitySoftware and Application Tools


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 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


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

mailto:[email protected]

mailto:[email protected]

Business

ABB Consulting and Full Service-The road to efficiency and reliability-april2013