Consulting services for all industries ABB Reliability Fingerprint Identifies opportunities for productivity, reliability and cost improvement
If only it were this simple… I found the problem. The batteries are upside down. © ABB Group 16 March 2018 | Slide 2
Introduction § § 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 § © ABB Group 16 March 2018 | Slide 3 Plant automation provides abundant and valuable process, production and equipment data Recommendations for sustainable productivity, reliability and cost improvements are provided
Benefits § § 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 § © ABB Group 16 March 2018 | Slide 4 Develops snapshot of current practices Qualifies and quantifies opportunities
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 § © ABB Group 16 March 2018 | Slide 5 Evaluates roles and responsibilities, reliability training, failure analysis § Reliability-centered maintenance (RCM) § Root cause analysis (RCA)
Description § Periodic assessment § Price based on number of Full-time Maintenance Employees (FTEs) § § Performed by Reliability Service team § § § 2 -Week program (week 1: data gathering, week 2: analysis and reporting offsite) 1 -2 consultants per week Deliverable § § © ABB Group 16 March 2018 | Slide 6 $15, 000: <50 FTEs $20, 000: 50 -100 maintenance FTEs $25, 000: 100+ maintenance FTEs Qualitative assessment of plant reliability and improvement plan Quantitative assessment of financial business opportunities
Paper Machine (PM) example From the base data provided: § § PM 1 loss est. at 1, 163 tons 10% improvement Year 1 = $34, 890 (10% x 1, 163 x $300) PM 2'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: Additional 10% PM 1 increase PM 2 = $31, 401 = $67, 419 Total for both machines Year 2 = $98, 820 Each extra or marginal ton of PM 1 availability = $300 ($756/hour) © ABB Group 16 March 2018 | Slide 7
1. OEE assessment Evaluates process and assets Maintenance Mgr. Production Mgr. Equipment Availability (A) Financial Mgr. Production Rate (P) People HR Manager Product Profit Plant VP/Manager § § § © ABB Group 16 March 2018 | Slide 8 Applies proven analysis methodology Measures relationships § Equipment availability § Production efficiency § Rate of quality Uncovers potential benefits Quality Mgr. Quality Factor (Q) Material Supply Manager
2. Maintenance Performance Assessment Includes maintenance cost Financial Mgr. Maintenance Mgr. People Production Mgr. Product HR Manager Quality Mgr. Material Supply Manager Profit Plant VP/Manager Utilization § Time spent waiting § Craft coordination § Availability of drawings § Craft flexibility § Parts availability § Level of rework © ABB Group 16 March 2018 | Slide 9 Methodology • Business processes • Planning • Special tools • Scheduling • Standard jobs library • Rebuild procedures Performance • Skills • Training • Job interruptions • Supervision • Morale • Labor issues • Precision maintenance
3. Reliability Culture Assessment: Roles and responsibilities, reliability training, failure analysis Financial Mgr. Maintenance Mgr. People Production Mgr. Product HR Manager Quality Mgr. Material Supply Manager Profit Plant VP/Manager § § § © ABB Group 16 March 2018 | Slide 10 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
Primary Activities 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 Analysis (off-site) 1 Week off-site § § § § © ABB Group 16 March 2018 | Slide 11 Develop Metric Charts Draw Cost/Structure Conclusions from Metrics Finalize OEE Calculations Develop OEE Waterfall Develop Business Case with ABB Account Personnel Develop Findings Presentation Complete Executive Summary Delivery (on-site) § Present Reports
Assessment Evaluation § § © ABB Group 16 March 2018 | Slide 12 The assessment findings are reviewed by a collaborative Reliability/ABB Field Services Team The team maps service portfolio opportunities to identified performance gaps
OEE Overview Total Available Production Time Nonproduction time Planned production time Net operating time Valuable operating time OEE % © ABB Group 16 March 2018 | Slide 13 = Equipment failure Availability Losses Gross operating time Set-up and adjustments Idling and minor stoppages Speed Losses Reduced speed Defects in process Quality Losses Availability factor (A) Planning Factor (Pf) Start-up losses X Performance factor (P) X Quality factor (Q) = Availability Factor (A) Performance Factor (P) Quality Factor (Q) Valuable operating time Planned production time
Sample Deliverable OEE Waterfall – PM 1: OEE = 75% PM 1: OEE = 75 % 0 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) © ABB Group 16 March 2018 | Slide 14 1, 000 2, 000 3, 000 4, 000 5, 000 6, 000 7, 000 8, 000 9, 000
Maintenance Performance Example: 20 Maintenance Cost is tied to: Maintenance cost as % of facility replacement cost World class 1. 5% – 2. 0% § § § 14 Your facility 12 § § 10 Example PM#1 - Vibration detects bearing wear 8 § 6 4 § 2 0 5 10 15 20 25 30 Facility number © ABB Group 16 March 2018 | Slide 15 Effectiveness of maintenance Skill level and quality of knowledge of personnel Asset type % of unplanned maintenance % of predictive maintenance 35 40 45 Proactive Maintenance Bearing is changed (cost $5, 000) Reactive Maintenance Bearing is not changed, Machine fails (cost $100, 000)
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