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Abb solutions-for-asset-management-the-competitive-advantage2238

  1. 1. ABB Asset Management PortfolioABB solutions for asset managementThe competitive advantage for everyindustry
  2. 2. Introduction and benefitsIntroductionKnowledge is the most precious commodity in businesstoday. Production facilities employing real-time Plant AssetManagement (PAM) systems significantly increase processuptime while reducing maintenance costs. The typical plantis teeming with information. The challenge, however, ishaving relevant information available at the right time, inthe right form and to the right people.ABB provides asset management solutions that presentreal-time asset information seamlessly and in the propercontext, to operations, maintenance, engineering andmanagement. As a result, continuous improvementinitiatives such as Reliability Centered Maintenance (RCM)strategies, plant-wide adoption of proactive maintenancepractices and autonomous maintenance minimizeunscheduled shutdowns, optimize product quality andbecome more effective. These activities can be employedregardless of industry. The results are higher return onassets and greater profitability.Customer Plant Asset Management NeedsABB’s Asset Management Portfolio Employee Energy Green Maintenance Tracking Alarm Risk Remote Asset Mgmt Health & Mgmt Initiatives Strategies Assets Mgmt Mgmt Diagnostic Benchmarking Safety ServicesAsset Optimization YES YES YES YES YESEngineering Services YES YES YES YES YES YESConsult IT YES YES YES YES YES YESServices and Projects YES YES YESReliability Services & Consulting YES YES YES YES YES YES YES2 ABB Asset Management Portfolio | ABB System 800xA
  3. 3. The primary benefits of an asset management strategy areincreased asset availability and performance, and maximizedoperations and maintenance effectiveness.Your optimization strategy – Asset Management Benchmarking ServicesAn effective asset management strategy combines the needs – Field Serviceof the production and maintenance organizations. It increases – Remote Diagnostic Servicesboth equipment availability and production rate by providing – Service Reportsinsight into asset health, corrective action instructions – Periodic Auditsand organizational visibility. It reduces time-to-decision and – Remote Connectionscoordinates production and maintenance activities. – – Support Line – CMMS CapabilitiesWhat ABB provides – Mobile Worker ConceptABB has a unified approach to Asset Management, with a – Terminal Servicesportfolio of solutions that is unmatched in today’s market as – IE 6.0you can see from the chart on facing page. ABB has at least – Smart Clientone solution (usually a few!) for every asset management need, – Back Office Maintenance Department Conceptregardless of industry or scope. – Risk Management – Employee Health and SafetyABB offers solutions supporting the following asset – Collaborative Device Communitiesmanagement tools and strategies: – IT Security– Condition Based Monitoring– Predictive Maintenance ABB’s answer to meeting the asset management needs of– Instrumentation Health the process control industry is our Asset Management– Process Optimization Portfolio (AMP). AMP includes the following:– Energy Management – Engineering Excellence - Engineering Services Group– Alarm Management – Maintenance Methodology - Reliability Services Group– Green Initiatives – Hands-on Expertise - Full Service Sites– Operator / End-User Training – Implementation Capabilities - Consult IT & Projects Groups– Reliability Dashboards – Remote Diagnostic Services - Service Group– Historical Analysis – All Encompassing Asset Monitoring capabilities with– Tracking Assets System 800xA– Lifecycle Cost Planning– Best Maintenance Practices & Strategies In this brochure, we’ve described most of ABB’s Asset– Hazard and Risk Studies Management offering. We are constantly adding to this– Health, Safety, and Environmental Issues portfolio. For the latest information, contact your ABB– Compliance Issues representative or visit www.abb.com.CMMS Reliability Overall Compliance Hazard Lifecycle Process Asset SystemSupport Mgmt Equipment Issues & Risk Training Cost Optimization Mgmt Asset Effectiveness Studies Planning Pilot SecurityYES YES YES YES YES YES YES YES YES YES YES YES YESYES YES YES YES YES YES YES YES ABB System 800xA |ABB Asset Management Portfolio 3
  4. 4. ABB System 800xA Asset OptimizationDescription Using Industrial IT patented Aspect ObjectTM technology,ABB provides 800xA Asset Optimization - a plant asset System 800xA collects and displays all information required tomanagement solution that presents real-time information seam- install, operate and maintain each component with a single clicklessly and in the proper context to operations, maintenance of the mouse. See Figure 1. For asset optimization features,engineering and management. these aspects are simply assigned to the appropriate object (asset); making them automatically available in each object’s800xA Asset Optimization provides real-time asset monitoring, use instances.notification and maintenance workflow optimization of auto-mation equipment, plant infrastructure, plant equipment, field In general, 800xA Asset Optimization features can bedevices, IT assets and production processes. 800xA Asset categorized into two user beneficial areas:Optimization (AO) is unique in the marketplace, in that it brings – Increased asset availability and performancetogether, in one user interface, all information resident in – Asset Condition Monitoringdifferent, traditionally disparate, automation and monitoring – Asset Condition Reportingsystems to provide a composite view of the health and – Optimized Operations and Maintenance effectivenessperformance of an asset. Transparently maintaining all the – Computerized Maintenance Management Systemrichness of information, advantages and capabilities of each (CMMS) Integrationspecialized system, AO eliminates the need for the user to – Instrumentation Management System (IMS) Calibrationswitch between several systems, workplaces, application Integrationenvironments and navigation schemes. AO includes software that monitors asset performance. WhileAO features are provided as extensions to Process Portal. While retrieving data from and interacting with multiple data serversthis solution functions as fully integrated capabilities of ABB’s (real-time data servers, OPC ® servers, etc.), asset monitorsSystem 800xA, it is also available as a stand-alone solution. use real-time plant information as inputs to detect health and performance conditions, assist in diagnosis of the problem and to offer correction recommendations.4 ABB Asset Management Portfolio | ABB System 800xA
  5. 5. AO includes a base set of asset monitors. Asset monitors vary Drives Monitor is explained in greater detail elsewhere inin complexity from those that simply identify status changes this document.in an intelligent device or identify high, low, or deviation limitconditions in the control system, to those that utilize advanced Based on ABB’s Drives Monitor system, the PCMS (Propulsionprocess equipment condition monitoring applications. When a Condition Management System) integrates data fromperformance condition is detected, the asset monitor issues an propulsion chain assets and creates predictive diagnosticAsset Condition Document (ACD) and notifies the system. algorithms for optimizing energy efficiency and performance of the propulsion system at the latest stage.An ACD contains all information necessary to describe an assetcondition. In turn, this information may be used to generate The MNS iS Asset Monitor is an intelligent supervisor ofa work order for maintenance purposes. Asset monitors can MNSiS low voltage switchgear. It uses several tools andexist in any part of the plant hierarchy, such as the device, loop, functions to provide information for Failure Management,equipment, process, plant or enterprise. They can be written for Maintenance Management and Asset Management.higher-level assets (parents) that are themselves composedof many subassets (children). In addition, System 800xA Compressor/Pump Curves Asset Monitors monitor the healthpre-configured asset monitor types are available for assignment of rotating equipment such as compressors, turbines, pumpsto assets of all levels. and fans; using a performance approach. Information such as pump curves is digitally scanned and imported into SystemField Device asset monitors for HART®, Foundation Fieldbus™ 800xA. The expected performance information is thenand PROFIBUS devices are available as part of the respective compared to the actual performance.Device Libraries provided with System 800xA DeviceManagement. Field Device asset monitors can be generic or Protective Relay electrical device asset monitors predictdevice-specific. The proper asset monitor is automatically MV/HV circuit breaker life, relay status, network issues andassigned to individual plant devices. other critical substation functions. For proper functioning of the circuit breaker, it is essential to monitor the circuit breakerThe Device Libraries are extended with devices from ABB and operation, spring charge indication, breaker wear, travel time,other manufacturers on a continuous basis. number of operation cycles and accumulated energy. Select models of Protective Relay electrical device asset monitorsABB also offers complex and custom asset monitors. Here’s a predict MV/HV circuit breaker life, manage denial of serviceshort list. attacks, log in failures and station battery supervision.Instrument Management System is an engineered solution ABB’s Universal Motor Controller, the UMC22, isbased on standard technologies like DBMS, OPC, XML and designed for protection and supervision of fixed speed lowWeb Services. It allows integration between System 800xA and voltage AC motors. It is based on Device Type Managementa third party calibration application. System 800xA is no longer (DTM) for user friendly configuration and parameterization. Ittied to Meriam DMS only. Other instrument management system monitors both electrical and mechanical conditions of the motor,provider applications can now be integrated into System 800xA. UMC22 electronics plus issues related to Contactors.The levels of integration are determined by the openness of thecalibration application. The Control Loop Asset Monitor (CLAM) is designed to monitor in real-time the quality and performance of processHeat Exchanger Asset Monitors alert process and control loops in control systems in order to bring actionablemaintenance personnel when the operation of a Heat Exchanger information on loop quality and performance to controlhas indicated a significant decline in performance, due to either engineers. By providing this information on control loopsfouling, or a significant change in operating point. directly to the operator screen, information is delivered to plant operations and maintenance personnel in a timely manner.The Drives Monitor enables careful monitoring of the condition It requires only three inputs: Process Value, Setpoint andand performance of an MV drive system, collection of data Control Output.and historical data storage; all from a remote computer. The ABB System 800xA |ABB Asset Management Portfolio 5
  6. 6. Additionally, ABB creates custom asset monitors using ABB’s Other well known solutions available on the market todayAsset Optimization Software Development Kit. For the latest list are very costly or offer limited monitoring of hardware only.of integrated devices and their corresponding asset monitors, ABB’s PNSM provides a cost effective solution with a farplease contact your ABB representative. broader range of monitored components. It is also delivered complete with pre-configured libraries of IT Assets representingBenefits of 800xA Asset Optimization (AO) include: devices and system processes widely used within industrial– Complete Asset Optimization businesses. – A single interface for operations, maintenance, engineering, and management to optimize asset availability and utilization Asset Vision Professional– Reduced Time to Repair through Optimized Work Processes Asset Vision Professional is a software application from – Integration of disparate Computerized Maintenance ABB that runs on a standalone desktop or laptop PC. Management Systems (CMMS), IMS Calibration Systems, Intended for engineering and maintenance personnel, Asset Dynamic Overall Equipment Effectiveness (OEE) Tools and Vision Professional supports ABB and 3rd party devices control systems streamlines work flow between operations communicating via HART, PROFIBUS, and Foundation Fieldbus. and maintenance to reduce downtime As a comprehensive asset optimization tool, it provides online– Automatic Monitoring of Maintenance Conditions and offline device configuration, parameter setting functions, – Real-time monitoring and alarming of asset Key online monitoring and tuning, diagnostic alerts, asset Performance Indicators (KPI’s) facilitate fast, reliable monitoring, calibration management and integral work implementation of corrective actions order processing.– Plant-Wide Adoption of Predictive and Proactive Maintenance Strategies Asset Vision Professional leverages off of ABB’s existing 800xA – AO collects, aggregates, and analyzes real-time plant asset System software by re-using its powerful device management information to provide advanced warning of degrading capabilities. Greater integration with a control system at the performance and impending failure, a critical component of field instrument level allows customers to start with a small any Reliability Centered Maintenance (RCM) strategy maintenance based application like Asset Vision Professional– Consistent Reporting of Plant Asset Health and grow it into a larger 800xA control system using the same – Visualization of current health conditions with Analysis configuration data and navigation methods for both. In addition features provides the ability to drill down to the root cause to support of the 3 major fieldbuses, Asset Vision Professional of failure supports a number of other options. Integrated calibration using the Mobility hand-held calibrator is one. Additional options for800xA Asset Optimization PC, Network and adding asset condition monitoring and CMMS interface areSoftware Monitoring provided in support of asset optimization. An option for SMSABB’s PC, Network and Software Monitoring (PNSM) Solution messaging to cell phones and pagers is also supported.will tell you about software and hardware issues before theyaffect production. 800xA Asset Optimization provides asset Benefits of Asset Vision Professional include:monitor types for a predefined set of IT assets commonly – Integrated Extended Automation Environmentassociated with the 800xA system, such as printers, computers, – Seamlessly integrates fieldbuses and field devicesswitches and software programs. The optimal behavior of these enabling system level engineering and maintenanceassets has significant impact on daily performance. For – Freedom of Choiceexample, consider the impact when performing with low free – Supports a full range of fieldbus and HART enableddisk space, at a high CPU load, with high amounts of network devicestraffic or with faulty switch ports. Specifically, these asset – Information Availabilitymonitors can identify the root cause of IT performance problems – The right information is available at the right time andby assessing conditions from the simple (printer out of paper), place. All relevant device status and diagnostic informationto the sophisticated (detection of a slow memory leak in is available across the whole lifecyclethe computer). – Complete Asset Optimization6 ABB Asset Management Portfolio | ABB System 800xA
  7. 7. AO offers reduced time to repair and consistent reporting of plantasset health. – Provides a single interface for engineering and notification of plant maintenance and asset optimization information– Automatic Monitoring of Maintenance Conditions – Real-time monitoring and alarming of asset Key Performance Indicators (KPI) facilitates fast, reliable implementation of corrective actions– Plant-Wide Adoption of Predictive and Proactive Maintenance Strategies – Collects and analyzes real-time plant asset information to provide advanced warning of degrading performance and impending failure– Consistent Reporting of Plant Asset Health – Reporting features provide visualization of current health conditions via the Asset Vision Professional workplace– Reduced Time to Repair via Optimized Work Processes – Integration of computerized Maintenance Management System (CMMS) and DMS provides users with a single view, leading to an efficient maintenance responseDriveMonitorTMEffective drive system lifecycle management requirescontinuous tracking of asset history – operation, wear, damageand maintenance. Careful monitoring of the condition andperformance of assets allows the implementation of predictivemaintenance programs that significantly reduce maintenancecosts and the risk of failure. Without this information,performance suffers and maintenance costs rise.ABB Medium Voltage (MV) Drives, in cooperation wih ABBCorporate Research, has developed the DriveMonitorTM – acustomer support software package that allows an operator tomonitor the performance of an MV drive system, collect dataand store the drive’s history, all from a remote computer.DriveMonitor offers:– Cost-effective data collection and processing Due to their complex role in industrial processes, drives– Scalable tools that can be adapted to the nature of an asset generate and have access to large quantities of data. Though (value, status) normally used to support a drive’s controlling function, these– Expandability, to accommodate single or multiple asset data can also be used for diagnostic purposes. No additional objects able to apply rules of varying complexity to the measures are necessary as the data are already available. assets ABB’s DriveMonitor solution exploits this opportunity to the– Ability to acquire data from various sources, eg, drive benefit of its customers. systems, control systems, vibration measuring tools, manual entries and the asset itself ABB System 800xA |ABB Asset Management Portfolio 7
  8. 8. ABB ServicesDescription ULMA Web Inspection System ServiceABB Services Group offers traditional field service, support line ABB’s Web Inspection System Service provides a cost-effectiveand training via ABB University. audit of ULMA web inspection systems. ABB experts review preventive and corrective maintenance practices, tuning,They also provide value added services including: calibration, training and spare parts inventories and provide– Remote Diagnostic Services (RDS) recommendations for improved system performance and– ULMA Web Inspection System Service availability.– Performance Improvement Fingerprints Benefits of ABB’s Web Inspection System Service include:Remote Diagnostic Services – Maximized system performance, availability and dataABB Remote Diagnostic Services (RDS) combine secure remote integrityconnectivity with technical support capabilities to deliver – Minimized maintenance cost and downtimeenhanced support options. RDS enables real-time visibility – Enhanced system capabilityof asset information. Asset specific diagnostic applications – Lower overall system lifecycle costperform condition-based monitoring and real-time alarming.The ABB global support network offers the industry and product Performance Improvement Fingerprintsknowledge of experts from around the world. This, coupled with ABB’s Process Improvement Fingerprint solutions facilitateimmediate availability of critical asset information significantly the managerial decision process by focusing on high impactimproves diagnostic and response time. opportunities for improvement.Benefits include: Features include:– Reduced overall maintenance costs – Access to ABB optimization experts– Optimized asset performance – Process performance benchmarking– Real-time access and support – Detailed ROI-based improvement plan– Fast and automated information retrieval – Clear communications during data collection and diagnosis– Condition reporting enhancements activities Performance Fingerprints provide a clear path to quickly close performance gaps by using the proposed improvement plan. They also offer a solid foundation for continuous improvement based on data. There are Process Improvement Fingerprint solutions in multiple industries, with more additions always being made.8 ABB Asset Management Portfolio | ABB System 800xA
  9. 9. ABB ConsultITDescription Benefits include avoiding:ConsultIT is ABB’s technical construction arm. It provides high – Redesign in late stages due to insufficient systemvalue services that go beyond ABB’s traditional projects and performanceservices groups. ConsultIT is a global community of know-how, – Rework of configurations as a result of poor productcompetence and experience. utilization – Time delay because of inefficient fault analysis orIts expertise covers: troubleshooting– Application Consulting – Budget overrun due to engineering time and wasted effort– Custom Asset Monitor Development– IT Security / Networks– Fieldbuses and Devices– Data Management– Engineering Efficiency– Software Solutions– Improving Operator Effectiveness– Project Risk Reduction ABB System 800xA |ABB Asset Management Portfolio 9
  10. 10. ABB Engineering ServicesDescription Integrity ManagementABB Engineering Services provides a wide range of professional Integrity Management means different things to different people.engineering services to a broad spectrum of process industry ABB’s approach is applicable regardless of industry sector. Weand manufacturing customers. support our customers in all aspects of integrity, process safety and risk management. We help them assess risk throughoutWith a resource base of over 550 professionals with an the asset lifecycle. With our approach, companies can enhanceunrivalled knowledge of project management and functional their understanding of key vulnerabilities and risks, long-termengineering, uniquely coupled to a true operator’s perspective, investment planning, best practices, system and procedureABB Engineering Services has the technology to provide clients updating and personnel training and development.with practical, cost effective solutions to problems in both batchand continuous manufacturing environments. We help customers optimize Integrity Management throughout the lifecycle of their enterprise. Our approach is flexible enoughThe real focus of ABB Engineering Services is on bottom line to enable review of a complete plant or to concentrate on aprofits and compliance issues. particular problem on one piece of equipment. Whatever we do, it is accompanied by knowledge transfer, tailored to the user’sServices Include: needs.– Operations & Maintenance– Hazard & Risk Studies Unlike others we only do detailed equipment analysis when it is– Health, Safety and Environmental Issues beneficial to the customer - this highly cost effective approach– Reduction of Energy Consumption is only possible because our industry recognized consultants– Improved Reliability apply their professional judgement, supported by our leading– Improved Asset Integrity methodologies and tools. If you have an existing approach we– Resolution of Compliance Issues help you improve it. If you don’t; we can help you develop one.Two examples of Engineering Services are Integrity Benefits of ABB’s Integrity Management include:Management and Total Asset Management. – Improved asset integrity and safety – Legislative and regulatory compliance – Best practices and performance improvements – Maintaining production – Enabling informed business decisions – Recognition of the real issues and focus on the real needs - saving time and money – Knowledge transfer - letting you continue Integrity Management into the future10 ABB Asset Management Portfolio | ABB System 800xA
  11. 11. The real focus of ABB Engineering Services is on our customers’bottom line profits and compliance issues.Total Alarm ManagementAre you familiar with the guidance in EEMUA 191?Do you wish to improve the performance of your alarmsystems?Can you demonstrate good management of your alarmhandling systems?ABB has a significant history of successful alarm improvementprojects based on our operational experience and a broadrange of professional skills, supported by a wealth of expertisein related topics. We have experience with continuousprocesses and the special requirements of batch systems.We can help with the practical implementation of all phasesof an alarm improvement initiative. Our expertise is backedby tools and techniques. Our service focuses on operationalissues, not the technology. Components include initial healthcheck, followed by planning for improvement, implementation,review and training.ABB’s Total Alarm Management provides technical servicesincluding license to operate, integrity management, operationsimprovement and capital investment to customers in thechemical, petrochemical, oil & gas, pharmaceutical,metals, pulp & paper and consumer industries worldwide.Total Alarm Management from ABB helps you achieve:– Improved HS&E performance– Fewer and shorter plant outages– Improved product consistency and quality– More focused maintenance– Improved operator environment and reduced operator stress ABB System 800xA |ABB Asset Management Portfolio 11
  12. 12. ABB Reliability ServicesDescription Total Plant ReliabilityABB offers a full range of services to improve the reliability and ABB Reliability Services offers an improvement strategy forperformance of manufacturing plants. When your plant operates process plants that works – Total Plant Reliability (TPR). TPRwell, capacity increases and manufacturing costs decrease. helps corporations increase profits and maximize production of quality products. Through TPR, corporations can achieve aWe help you to optimize the performance of your plant through return on investment of three to one.its lifecycle with consulting services in the following areas:– Asset Care TPR is a multi-staged improvement program comprised of four– Operational Plant Support key elements. These elements focus on improved leadership for– Total Plant Reliability® and management of your organization’s assets and people:– PM30 Plus – Focused Empowerment– Asset Performance Management – Shared vision, mission & expectations, roles &– Plant Performance Benchmarking responsibilities, operator driven reliability, market-based– World Class Reliability® Assessment maintenance, lean organization, end entitlement and– CMMS Assist leadership skills– Real Time Production Intelligence – Asset Management – Proactive planning, scheduling, turnaround optimization,ABB’s Reliability Integrated Solution CMMS, materials management, operator maintenance andABB’s Reliability Integrated Solution increases asset reliability outsourced asset managementand productivity while maximizing the return on your – Maintenance Preventionmaintenance investments. Our solution provides you with insight – Preventive & predictive maintenance, failure analysis,into your assets’ health, corrective action instructions and de-bottlenecking optimization, RCM2, RBI, concurrentorganizational visibility. We begin with a site audit, which engineering, process engineering and skills trainingprovides benchmarking data to establish the baseline for – Balanced Scorecardimprovement. Using this gap analysis, we develop a customized – Align incentives, communicate goals, performanceplan by leveraging the experience of our people as well as the development, financial performance, learning & growth,extended features of our products. Our approach results in customer / partner and internal systemscontinuous service improvements and sustainable maintenanceoperations while minimizing safety and environmental risks. PM30 Plus ABB Reliability Services offers a disciplined reliability processThe world-class Overall Equipment Effectiveness (OEE) score that drives improved utilization of assets and resources,is 85%. Do you know where you stand? Unexpected failures increased efficiencies and reduced costs. ABB uses CMMS/and poor quality products can be devastating to profit goals. EAM software as an enabler for the entire reliability process.You need to know how your equipment is performing, how to The process works with any well-developed CMMS - oravoid failures and where you have production losses. ABB’s customers can opt to use ABB’s software, PM30 Plus. OurReliability Integrated Solution enables you to measure OEE, software grew out of 35 years of experience in implementingmonitor production assets and control loops as well as and administering over 1,500 reliability initiatives. Eachmanage device calibration. function within your organization can access consistent information and expert analysis on how your business isABB has developed a phased implementation approach that running. Improve data quality and increase planning accuracyconsists of benchmarking assessments, database development, with ABB’s PM30 Plus.CMMS deployment and continuous service improvements.12 ABB Asset Management Portfolio | ABB System 800xA
  13. 13. ABB Reliability Services offers a disciplined reliability process thatdrives improved utilization of assets and resources, increasedefficiencies and reduced costs.World-Class Reliability ® Assessment CMMS / EAM Implementation Services -ABB Reliability Services provides solutions that improve safe- CMMS ASSISTty, compliance, and profitability. The World Class Reliability TM ABB Reliability Services’ team is comprised of experienced(WCR) Benchmark is a product of 40 years development. The maintenance and reliability professionals, with a track recordbenchmark process identifies best practices and compares an of many CMMS / EAM (Computerized Maintenance Manage-organization’s performance level with other companies and ment / Enterprise Asset Management System) implementationsindustries in order to set an improvement goal. Qualitative and management consulting engagements for over 40 years.and quantitative analyses are conducted of both reliability and Our reputation is based on developing successful implementa-maintenance practices, resulting in: tion strategies that are rapid, business driven and focused on– Identification of performance gaps accomplishing corporate reliability goals and maintenance– Development of strategic and tactical plans to close spending targets. Our approach is unique with a strong performance gaps emphasis on Reliability Centered Maintenance.– Creation of a business case documenting the financial impact of addressing areas of opportunity We apply the following principles to all our EAM implementations:Experience has demonstrated that objective evaluation is the – Business Process Prototypingindispensable first step in developing a manufacturing process – defining detailed application functionality based onthat integrates departments, fosters teamwork and promotes “optimized”, “to-be” business processesemployee involvement. The bottom line is measurable – Package Deploymentperformance improvement in: – highly modular– Capital and operating costs – Total Training Solution– Maintenance labor and materials – leading edge, hands-on, multi-medium training solutions– Production throughput are absolutely necessary for organizational assimilation of– Equipment availability, run rates and quality today’s highly complex, IT driven EAM applications– Safe work practices – Full Knowledge Transfer– Environmental compliance – ensures that your team becomes self-sufficient, rather than consultant-dependent – Three (3) Tier Reliability Metrics Hierarchies – well defined, cascading metrics for Shop Floor, Line Management and Executive levels ABB System 800xA |ABB Asset Management Portfolio 13
  14. 14. Our consultants have assisted companies in Pulp & Paper, that improves plant productivity by identifying ways toPharmaceuticals, Cement, Plastics, Steel, Mining and Metals increase Overall Equipment Effectiveness (OEE), a crucial KPIprocessing and Refining. ABB supports the following popular that drives return on assets. This user-friendly softwareEAM applications: automates data-collection and analysis, and provides– SAP-PM, MM and PS modules – from SAP customized reports tailored to plant management’s needs.– MAXIMO (Version 4 and 5) from MRO software Real-TPI harnesses the analytical power of three of the standard– MP2, MP5 and D7i from Data Stream production evaluation processes:– Passport and EMPAC from Indus Corporation – OEE– EAM and EXP (Version 3) from IVARA Corporation – Root Cause Analysis (RCA) – Total Productive Maintenance (TPM)ABB offers a highly detailed, rigorous, business mapping andsystem configuration engagement that has enabled many When OEE indicates poor plant performance, RCA is utilizedcompanies to enhance the service management functionality in to determine what the problem is and where it is located sotheir CMMS/EAM. the corrective action can be taken. TPM is a process to adjust production equipment procedures with the aim of improvingReal Time Production Intelligence efficiency. Real-TPI is designed to improve efficiency andOne of the most difficult issues facing manufacturers today is positively influence ROI by facilitating the elimination of failuresoptimizing existing production operations. Companies are in the early stage.striving to meet business objectives while facing an estimated40% waste of productivity through unplanned stops, Real-TPI:interruptions, speed losses, and quality defects. These – Provides solid, real-time performance data and advancedundetected losses comprise a company’s “hidden plant” tools for analysisproductivity opportunities. – Complements production planning, production tracking and financial systems with real-time production efficiency dataLeveraging “hidden plant” opportunities requires intimate – Supports TPM, SixSigma, Failure Modes Effects andknowledge of the factory’s true performance. Only through Criticality Analysis (FMECA) and other improvementconsistent, real time measurement and analysis of the methodologiesbusiness’s Key Performance Indicators (KPIs) is true – Easily tracks the daily progress and identifies possibleperformance measured and improved. problems in the production line – Supplies critical equipment behavior information, enablingReal Time Production Intelligence (Real-TPI) is a real time preventive maintenanceperformance measurement and analysis software solution – Eliminates inaccurate, time and labor-intensive manual logs – Enables the plant to perform smarter and at substantial cost savings, resulting in sustainable competitive advantage14 ABB Asset Management Portfolio | ABB System 800xA
  15. 15. ABB Full Service®Description Its benefits include:An ABB Full Service® partnership is a globally supported long- – Improved plant performanceterm, performance-based agreement in which ABB commits – Increased reliability and lifecycle of production equipmentto maintain and improve the production equipment. With a – Managed maintenance as a core competenceFull Service agreement, ABB takes over responsibility for the – Managed change and creation service cultureengineering, planning, execution and management of an entire – Access to resources and knowledge of ABB’s global networkplant’s maintenance activities. ConclusionABB Full Service is a plant reliability management program that Benefits of an asset optimization strategy extend beyond theturns maintenance operations into profit centers. By assuming maintenance organization to all the stakeholders throughout theresponsibility for a plant’s maintenance operations, ABB helps enterprise. An effective asset management strategy combinesimprove and sustain the performance of production assets. the needs of the production and maintenance organizations.ABB brings together world-class maintenance and reliability It increases both equipment availability and production rate bymethodologies, parts management, online tools, domain providing insight into asset health, corrective action instructionsexpertise and professional maintenance and P&L leadership to and organizational visibility. Its ability to share contextual infor-increase asset effectiveness while reducing maintenance costs. mation to those who need it — when they need it — reduces time-to-decision and coordinates production and maintenanceABB contractually commits to improvement in Overall activities. Executing an asset management strategy to increaseEquipment Effectiveness (OEE) over the span of the Full OEE and reduce maintenance costs can be a highly effectiveService Agreement. OEE, the industry-accepted measurement means to remain competitive in the marketplace.of production performance, is a function of three basicindicators: availability, performance efficiency and rate of ABB provides asset management solutions that presentproduct quality output. ABB’s contractual commitment to OEE actionable data seamlessly and in the proper context, toincludes a bonus for exceeding OEE goals, and a rebate for operations, maintenance, engineering and management. As acustomers if the goals are not met. result, continuous improvement initiatives such as Reliability Centered Maintenance (RCM) strategies, plant-wide adoption ofIn addition to OEE, ABB contractually commits to reduce overall proactive maintenance practices and autonomous maintenancemaintenance costs. Increased OEE and reduced costs yield minimize unscheduled shutdowns, optimize product qualitybottom-line results for ABB’s Full Service customers. Coupled and become more effective. These activities can be employedwith the new ability to focus on core business (rather than regardless of industry. The results are higher return on assetsmaintenance), Full Service improves the business on many and greater profitability.levels, making ABB customers even more competitive. ABB System 800xA |ABB Asset Management Portfolio 15
  16. 16. Contact usFor more information please contact: Note: 3BUS094559 We reserve the right to make technical changesABB AB or modify the contents of this document withoutOpen Control Systems prior notice. With regard to purchase orders,Västerås, Sweden the agreed particulars shall prevail. ABB doesPhone: +46 (0) 21 32 50 00 not accept any responsibility whatsoever forFax: +46 (0) 21 13 78 45 potential errors or possible lack of information inE-Mail: processautomation@se.abb.com this document.www.abb.com/controlsystems We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to thirdABB Inc. parties or utilization of its contents - in wholeOpen Control Systems or in part - is forbidden without prior writtenWickliffe, Ohio, USA consent of ABB.Phone: +1 440 585 8500Fax: +1 440 585 8756E-Mail: industrialitsolutions@us.abb.com © Copyright 2010 ABB.www.abb.com/controlsystems All rights reserved.ABB Industry Pte LtdOpen Control SystemsSingaporePhone: +65 6776 5711Fax: +65 6778 0222E-Mail: processautomation@sg.abb.comwww.abb.com/controlsystemsABB Automation GmbHOpen Control SystemsMannheim, GermanyPhone: +49 1805 26 67 76Fax: +49 1805 77 63 29E-Mail: marketing.control-products@de.abb.comwww.abb.de/controlsystems

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