abb reliability fingerprint consulting services for all industries identifies opportunities for...
TRANSCRIPT
ABB Reliability FingerprintConsulting services for all industries
Identifies opportunities for productivity, reliability and cost improvement
© ABB GroupApril 18, 2023 | Slide 2
If only it were this simple…
I found the problem. The batteries are upside down.
© ABB GroupApril 18, 2023 | Slide 3
Introduction
Plant automation provides abundant and valuable process, production and equipment data
The ABB Reliability Fingerprint collects and evaluates site data to identify opportunities for productivity, reliability and cost improvement
Collected data is used to benchmark your site against leading process industry and manufacturing sites
Areas of opportunity are identified and evaluated by ABB process and industry experts
Recommendations for sustainable productivity, reliability and cost improvements are provided
© ABB GroupApril 18, 2023 | Slide 4
Benefits
Develops snapshot of current practices
Benchmarks site against industry best practices
Establishes recommendations for site performance improvement
Identifies both short and long term benefits
Quantifies potential benefits Productivity improvement (OEE) Cost optimization Reliability
Develops a strategy that will deliver benefits
Qualifies and quantifies opportunities
© ABB GroupApril 18, 2023 | Slide 5
Three-part assessment
1. Overall Equipment Effectiveness (OEE) Composite measure of equipment availability, production
rate and quality
2. Maintenance Performance Evaluates maintenance practices:
Utilization, Methodology, Performance
3. Reliability Culture Evaluates roles and responsibilities, reliability training,
failure analysis Reliability-centered maintenance (RCM) Root cause analysis (RCA)
© ABB GroupApril 18, 2023 | Slide 6
Description
Periodic assessment
Price based on number of Full-time Maintenance Employees (FTEs)
$15,000: <50 FTEs $20,000: 50-100 maintenance FTEs $25,000: 100+ maintenance FTEs
Performed by Reliability Service team 2-Week program
(week 1: data gathering, week 2: analysis and reporting off-site)
1-2 consultants per week
Deliverable Qualitative assessment of plant reliability and improvement
plan Quantitative assessment of financial business opportunities
© ABB GroupApril 18, 2023 | Slide 7
Paper Machine (PM) example
From the base data provided:
PM1 loss est. at 1,163 tons 10% improvement Year 1 = $34,890 (10% x 1,163 x $300)
PM2's loss est. at 2,497 tons 10% improvement Year 1 = $74,910 (10%x 2,497 x $300)
Total for both machines Year 1 = $109,800
During Year 2:Additional10% PM1 increase = $31,401 PM2 = $67,419
Total for both machines Year 2 = $98,820
Each extra or marginal ton of PM1 availability = $300 ($756/hour)
© ABB GroupApril 18, 2023 | Slide 8
1. OEE assessment
Applies proven analysis methodology Measures relationships
Equipment availability Production efficiency Rate of quality
Uncovers potential benefits
Evaluates process and assets
QualityFactor (Q)
Quality Mgr.
Production Rate (P)
Production Mgr.
EquipmentAvailability (A)
Maintenance Mgr.Financial Mgr.
HR Manager Supply Manager
Product MaterialPeople
Plant VP/Manager
Profit
© ABB GroupApril 18, 2023 | Slide 9
2. Maintenance Performance AssessmentIncludes maintenance cost
Utilization Time spent waiting Craft coordination Availability of drawings Craft flexibility Parts availability Level of rework
Methodology• Business processes• Planning• Special tools• Scheduling• Standard jobs library• Rebuild procedures
Performance• Skills• Training• Job interruptions• Supervision• Morale• Labor issues• Precision
maintenance
HR Manager
Plant VP/Manager
Supply Manager
Product
Profit
MaterialPeople
Quality Mgr.Production Mgr.Maintenance Mgr.Financial Mgr.
© ABB GroupApril 18, 2023 | Slide 10
3. Reliability Culture Assessment:
Review maintenance practices and maintenance culture (planning and scheduling effectiveness)
Understand plant reliability culture
Identify perceived strengths and improvement opportunities
Review organizational structure (job responsibilities, ratios)
Identify maintenance and reliability gaps
Roles and responsibilities, reliability training, failure analysis
HR Manager
Plant VP/Manager
Supply Manager
Product
Profit
MaterialPeople
Quality Mgr.Production Mgr.Maintenance Mgr.Financial Mgr.
© ABB GroupApril 18, 2023 | Slide 11
Primary Activities
Analysis(off-site)
Delivery(on-site)
Information Gathering(On- and off-site)
1 Week on-site Pre-arrival data collection packet
Collect Data on-site Validate Data Confirm information understanding with Customer
1 Week off-siteDevelop Metric ChartsDraw Cost/Structure Conclusions from Metrics
Finalize OEE CalculationsDevelop OEE WaterfallDevelop Business Case with ABB Account Personnel
Develop Findings PresentationComplete Executive Summary
Present Reports
© ABB GroupApril 18, 2023 | Slide 12
Assessment Evaluation
The assessment findings are reviewed by a collaborative Reliability/ABB Field Services Team
The team maps service portfolio opportunities to identified performance gaps
© ABB GroupApril 18, 2023 | Slide 13
OEE Overview
Valuable operating time
Net operating time
Gross operating time
Total Available Production Time
Planned production timeNon-
productiontime
AvailabilityLosses
SpeedLosses
QualityLosses
Equipment failure
Reduced speed
Defects in process
Set-up and adjustments
Idling and minor stoppages
Start-up losses
QualityFactor (Q)
AvailabilityFactor (A)
PerformanceFactor (P)
Availabilityfactor
(A)
Performancefactor
(P)
Quality factor
(Q)
Valuable operating time
Planned production time
OEE% = X X =
PlanningFactor (Pf)
© ABB GroupApril 18, 2023 | Slide 14
Sample DeliverableOEE Waterfall – PM 1: OEE = 75%
PM 1: OEE = 75 %
Total Time (hours) (8760 hrs)
Steam (2 hrs)
Electrical (98.1 hrs)
Other (5.1 hrs)
Planned Production Time (8654.8 hrs)
Scheduled Total Outages (294 hrs)
Electrical (120.9 hrs)
Mechanical (191.4 hrs)
Roll Failures (59 hrs)
Instrumentation (6.9 hrs)
DCS (15.2 hrs)
Hydraulics (4.1 hrs)
Drives (13.7 hrs)
Operations (332.4 hrs)
Breaks (410 hrs)
Available Time (7207.2 hrs)
Quality Losses (730 hrs)
Making Good Product at MPR (6477.2 hrs)
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000
© ABB GroupApril 18, 2023 | Slide 15
Maintenance Performance Example:
Maintenance Cost is tied to: Effectiveness of maintenance Skill level and quality of
knowledge of personnel Asset type % of unplanned maintenance % of predictive maintenance
Example PM#1 - Vibration detects bearing wear
Proactive Maintenance - Bearing is changed (cost $5,000)
Reactive Maintenance - Bearing is not changed, Machine fails (cost $100,000)0
2
4
6
8
10
12
14
20
5 10 15 20 25 30 35 40 45
Ma
inte
nan
ce c
ost
as
% o
f fa
cilit
y re
pla
cem
en
t co
st
Facility number
Your facility
World class1.5% – 2.0%
Areas evaluated with fingerprint
Reliability Culture Areas
Roles and Responsibilities
Preventive & Predictive Maint.
Responsive Maintenance
Management Leadership
Organizational Structure
Supplier & Services - Stores
Physical Assets Program
Continuing Education
Performance Assurance
HighdB AvgSite ScoreLow
