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

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

  1. 1. Sammy Saba – Marketing and Sales Manager ABB Global Consulting – April 2013The road to Efficiency and ReliabilityABB Global Consulting and Full Service
  2. 2. ABB Global ConsultingOur portfolio 1/2 Portfolio Activities Definition / Scope Implementation and customization of CMMS System (SAP PM,INFOR EAM, MAXIMO, ABB…..) CMMS Design and Implementations of communication interface between ERP and CMMS System Analysis and optimization of Warehouse management Warehouse Management (Safety Stocks, Rotation Index, Min/Max Stock,..) Optimization Coding and Standardization of Spare Parts Efficiency Energy Efficiency audit Energy Efficiency UNI EN 50001 Implementation Improvement Feasibility Study (ROI & KPI’s Identification) Improvement action and Energy Efficiency Credit Management (TEE) Revamping Study of Electrical, Mechanical and Thermal Systems Equipment and Process Assessment (Electrical, Mechanical and Thermal) Engineering Activities Machinery re-certification Operational Engineering support RAM’s Analysis (reliability, availability and maintainability) Reliability Reliability Engineering RCM – RCA – RBI Analysis Improvement actions
  3. 3. ABB Global ConsultingOur portfolio 2/2 Portfolio Activities Definition / Scope Environmental Management System (ISO 14001) Operational Health and Safety Management System (OHSAS 18000) Safety & Environmental SIL - Safety Integrity Level Risk Assessment GxP Impact assessment (Good Laboratory / Manufacturing Practice)Safety, Quality Validation Process and Computer System Validation (GAMP 4 - Good Automated Manufacturing Practice) Equipment DQ, IQ, OQ, PQ (Design, Installation, Operational & Performance Qualification) and Metrological laboratory & calibrations Training 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 Training and Coaching Maintenance and 5S - Six Sigma methodology - Energy Efficiency Concept and Implementation - Warehouse management and optimization - CMMS Computerized Maintenance Management System
  4. 4. ABB Full ServiceOur portfolio Portfolio Activities Definition / Scope Operation & Maintenance is a long-term performance based on Operation & Maintenance partnership agreements on Lump Sum and KPI for all Maintenance and Operation activities Perfomance Full Service contract is a long-term performance based on partnership Full Service Based agreements based on Lump Sum and KPI for all Maintenance activities Agreements Equipment Performance Full service o Global Service of Maintenance related to the specifics Management Equipment (e.g.: Motor, Instruments.) based on Lump Sum and KPI Asset Management for Fuel Global management of the activities directly and indirectly linked to the Retail Stations Maintenance of fuel retail networks and of the relevant services TAM (Turn-Around Maintenance) consists in all the cyclical and also Turn-Around Maintenance Maintenance extraordinary strategic maintenance activities planned and managed (TAM)Management & during the stop planned production. Supervision Maintenance Management Maintenance Management & Supervision consists in the leading & Supervision Maintenance workforce and supervisor of the work Improve OEE, reduce Maintenance spend, optimize resources and stock Maintenance & Maintenance & Productivity inventory, minimize risk, RCA, FMECA analysis, CMMS Implementation Productivity Implementation and managementImplementation and EEI Energy Efficiency Feasibility Study on electrical and thermodynamic equipment and Improvement implementation projects with performance based contract (EPC)
  5. 5. ABB Efficiency and Reliability The approach Energy Plant Spare Parts Safety & Efficiency Reliability Optimization Environment Costs optimization Energy Saving Down Time Reduction Capex Reduction Safety & environment SW for Maintenance & Reliability SW for Energy Efficiency SW for Spare Parts Design: EMDS (Engineering Safety & environmental Implementation: E2P Optimization: ISPO Maintenance Design services, Process(Energy Efficiency Platform) (Inventory Spare Parts System), FMEA+CA (Failure Validation, Remediation, E2AM (Energy Efficiency Optimization), CODE mode Effects & Criticality Decommissioning, Asset Management) Analysis); SW for Maintenance MAKER (coding for spare Technical Training Path cpmPlus (Energy parts) Management: CMMS Management System) (Enterprise Asset Management) Training© ABB GroupApril 3, 2013 | Slide 5
  6. 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 GroupApril 3, 2013 | Slide 6
  7. 7. ABB global approach to Energy EfficiencyA complete process from analysis to implementation(EN 15900:2010) Energy Mapping Feasibility Realization Check-Up Flash Audit Detailed Measure andPHASE e Measurement Study Design of Verification Analysis of the Areas Analysis of Equipments Solution of Results Building Utilities Utilities Building Utilities Utilities Utilities Building Utilities Edifici Utilities Building Utilities Utilities Building Utilities Utilities Building Utilities Utilities Building Utilities UtilitiesAREA Prod. Prod. Prod. Prod. Organiz. Prod. Prod. Prod. Organiz. Organiz. Organiz. Organiz. Organiz. Organiz. Area Area Area Area Area Area Area Check-up Flash Feasibility Activities Description of Report AuditOUTPUT Energy Mapping Study Design and Supervision the energy Report Report scenario (Sankey diagram) technical Realization of specification achieved Solution Gap Return of Improvement identification Potential Investment Master Plan and analysis Carried out by the Customer Opportunity Trends in complete independence Portfolio analysis (*) Carried out by the Customer (*) In the absence of data, ABB With support of ABB specialists offers a measurement service for Improvement any vector personalized for the Opportunity Carried out by ABB specialists real needs of the Customer. Sheets Preliminary Energy Audit Implementation Verification Analysis© ABB GroupApril 2012 | Slide 7
  8. 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 GroupApril 3, 2013 | Slide 8
  9. 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© ABB GroupApril 3, 2013 | Slide 9
  10. 10. ABB Efficiency and Reliability Material Management and Optimization Roadmap – ABB Material Management and Optimization Model Commitment Mutual Pre-Analysis Performances Warehouse Warehouse Continuous Criticality Analysis Optimization Assessment Management Improvement Program ISPO – Inventory Spare Parts Optimization WMA WCI CONTINUOUS DESIGN & OPTIMIZATION MANAGEMENT MPROVEMENT Pre – Analysis Performances Assessment Criticality analysis Optimization Material Management WCI Program • Warehouse • Suppliers and Catalog analysis • Categories spares • Critical Spare • Trainings and Coaching of • Web Hosting Service for organization codification and Identification Warehouse Management stock analysis • Spares and Equipment • ERP / CMMS attribution relationships analysis • Inventory Indexes • Warehouse automations (RF- • Safety Stock systems • Modeling of Cost of Calculation RFID, standard barcode, QR..) management (min/max, • Spare Codification Design • Inventory data Stock Out of Q, EOQ, SS) • Safety Stock • Spare Part Tracking • Materials Management System Material (by FMECA, (last 3-years) definition by • Inventory yearly analysis analysis: goods Data collection (store investment, process and • Warehouse Management: Classes / Spare & revisions utilization db, inventory turnover,..) functionality, costs, Material handling, Purchasing, receipts, (Module B – D, safety & quality) virtual storage…. • Cost of stock out purchase orders, • Inventory Data collection: min/max, Q, consumption…. analysis and remediation  Material List • Critical Classes of EOQ,SS) • Supply chain management • Failure  Lead Time Materials Analysis (web-based) • FMECA analysis • Database  Price (Module A–B) Equipment updating • Spare parts standardization • Spare criticality  Consumption records • Critical Spare Parts and codification redefinitions  Plant Downtime cost • Reporting design • Spare parts and Analysis • Stock levels Monitoring (min / • Inventory Assessment Equipment • Material Models Design (Module C–D) max, Q, EOQ,Ss) relationships© ABB GroupApril 3, 2013 | Slide 10
  11. 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 GroupApril 3, 2013 | Slide 11
  12. 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 GroupApril 3, 2013 | Slide 12
  13. 13. ABB Efficiency and Reliability The road to efficiency and reliability - Assessment Energy Plant Spare Parts Safety & Efficiency Reliability Optimization Environment Check Up/ Safety & Opportunity Feasibility Warehouse Environment Identification/ Study Assessment Assessment Master Plan Energy Efficiency Performance Based Warehouse mgmt & Process Improvement Agreements Optimization Validation Maintenence Mgmt & Remediation & Supervision Decommissioning CMMS & Engineering Activities Reliability Engineering Training© ABB GroupApril 3, 2013 | Slide 13
  14. 14. ABB Efficiency and ReliabilityRoadmap Overview Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M 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 3, 2013 | Slide 14
  15. 15. ABB Efficiency and ReliabilityMutual Commitment Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M Agreement • Assessment and Project definition© ABB GroupApril 3, 2013 | Slide 15
  16. 16. ABB Efficiency and ReliabilityDesign Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M Module 1 • As is analysis • Strategy definition • Measurement system definition and implementat. • Reliability analysis and Implementat.© ABB GroupApril 3, 2013 | Slide 16
  17. 17. ABB Efficiency and ReliabilityImplementation Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M Module 2 • Computerized Maintenance Management System Impl. Module 3 Module 4© ABB GroupApril 3, 2013 | Slide 17
  18. 18. ABB Efficiency and ReliabilityImplementation Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M Module 5 Module 6© ABB GroupApril 3, 2013 | Slide 18
  19. 19. ABB Efficiency and ReliabilityImplementation Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M Module 7© ABB GroupApril 3, 2013 | Slide 19
  20. 20. ABB Efficiency and ReliabilityFollow-up – Coaching and training on the job Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM /AMF/FS/O&M Module 8© ABB GroupApril 3, 2013 | Slide 20
  21. 21. ABB Efficiency and ReliabilityMaintenance Management & Supervision Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M Maintenance Management & Supervision Work consists in leading Maintenance workforce Supervision and supervising the work. These modules include the following activities: planning & scheduling, works supervision and management, Maintenance Engineering analysis, Maintenance improvement design, performance monitoring, Management HSE and Quality management. Turn-Around Maintenance consists in all the cyclical and also extraordinary strategic Turn-Around maintenance activities planned and managed Maintenance during the stop planned production.© ABB GroupApril 3, 2013 | Slide 21
  22. 22. ABB Efficiency and ReliabilityPerformance Based Agreements Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M EPM Equipment Performance Management is specific Global Service of Maintenance related to specific Categories of Equipment (e.g.: cogenerations, motors, instruments, EPM drives, etc...) The Contract is based on Lump Sum price and KPIs. Asset 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 AMF relevant services ABB 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 & Full Service Mining, Oil & Gas, Petrochemical, Manufacturing, Chemical, Crane & Harbor, etc…) Operation & Maintenance Contract is a long-term performance based partnership agreement (Lump Sum price and KPIs) for all Operation and Maintenance activities Operation & (specifically for Power and Utility plants and industries) Maintenance© ABB GroupApril 3, 2013 | Slide 22
  23. 23. ABB Efficiency and ReliabilitySoftware and Application Tools Roadmap - Efficiency and Reliability Commitment Commitment Mutual Maintenance Performance Mutual Design Implementation  Follow-up Management Based & Supervision Agreements MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM/AMF/FS/O&M Software for Maintenance Software for Spare Software for Energy Software for Software for and Reliability Design: Parts Efficiency Productivity Maintenance Optimization: Implementation: Management Management: EMDS ISPO (Engineering Maintenance (Inventory Spare Parts E2P CPM+ CMMS (Energy Efficiency (Real-Time Production (Enterprise Asset Design System) Optimization) Platform) Intelligence) Management) FMEA + CA CODE MAKER (Failure Mode Effects and (Coding of spare parts) E2AM OEE Rec Criticality Analysis) (Overall Equipment (Energy Efficiency Asset Effectiveness Recorder) Management)© ABB GroupApril 3, 2013 | Slide 23
  24. 24. ABB Efficiency and ReliabilityWeb-based platform Internet CUSTOMER ABB H.Q. EMDS FMEA CA ISPO CODE OEE E2P E2AM CMMS eSOMS MAKER REC (CPM+) ABB Reliability & Maintainability platform ABB Energy ABB O&M platform Efficiency platform Software for Maintenance Software for Spare Software for Energy Software for Software for and Reliability Design: Parts Efficiency Productivity Maintenance EMDS Optimization: Implementation: Management Management: (Engineering Maintenance ISPO CPM+ CMMS Design System) (Inventory Spare Parts E2P (Real-Time Production (Enterprise Asset FMEA + CA Optimization) (Energy Efficiency Intelligence) Management) (Failure Mode Effects and Criticality Platform) Analysis) CODE E2AM OEE Rec eSOMS (Energy Efficiency Asset (Overall Equipment (Electronic shift MAKER Management) Effectiveness Recorder) Operat. Maint. (Coding of spare parts) System)© ABB GroupApril 3, 2013 | Slide 24
  25. 25. ABB Reliability & Maintainability platformKey relationships© ABB GroupApril 3, 2013 | Slide 25
  26. 26. Contacts FOR FURTHER QUESTIONS PLEASE CONTACT: e-mail: ABB.fullservice@it.abb.com e-mail: consulting.italy@it.abb.com© ABB GroupJuly 2nd 2012| Slide 26

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