PA LCS Services ABB’s Vision for Services · Advanced services: increasing customer loyalty and...

© ABB Group September 24, 2012 | Slide 1


PA LCS Services ABB’s Vision for Services


…When you can measure what you are

speaking about and express it in

numbers, you know something about it;

When you cannot measure it . . . your

knowledge is meager and unsatisfactory.

Lord Kelvin

OS -3

Production /OEE – Overall Equipment Effectiveness

Production Distribution:

Production

Increase

Availability

Unscheduled machine down time

Scheduled machine down time

Performance

Transitions

Sheet Breaks and Recovery time

Grade Changes and Change Time

Machine startups and start up time

Machine Speed

Slow Speed Changes – Operator changes

Uncoordinated changes

Mechanical Constraints

Trim Settings

Reel building

Quality

Variability Issues

Lab Test/ Defect limitations

Process disturbances

Target Shifting

Weight /Moisture Target shift

Steam availability and distribution

Original

Potential

qiQ

piP

aiA

QPAT

VV

VV

VV

VVVV

Defining the source and

magnitude of production

limitations points the way

towards removing production

barriers.


Global Service Activity Totals:

• 1,026,611 Service Hours

• 1,000,374 Service Work Orders

• 2600 Active Sites

• 1600 Service Engineers

Measuring Services


Actual ABB Service Evaluation at customer site

Manage Service Activity

Reduce Reactive Services - Don’t run to failure

Proactive

Reactive



ABB has services to help all along your plant lifecycle

Design

&

Construction

FeasibilityScreening

Installation

&

Commissioning

Warranty

&

Base Lining

Execution

ABB Service Timeline PortfolioABB Service Timeline PortfolioDesign & Construction Installation & Commissioning Warranty & Post-Warranty

DecommissioningFront-End

Engineering

Detail

Engineering

Equipment

Selection &

Procurement Construction Commissioning Start-Up Operation

Life Time

Extensions

Installation & Commissioning

Repairs & Interventions

Training

Evolution Services

Remote Services

Preventive Maintenance

Condition Monitoring

Advanced Industry Services

Upgrades & Retrofits

Spare Parts

Consulting (Energy Efficiency, Productivity, Reliability, Safety)

Full Service (Maintenance Outsourcing)

Design

&

Construction

FeasibilityScreening

Installation

&

Commissioning

Warranty

&

Base Lining

Execution

ABB Service Timeline PortfolioABB Service Timeline PortfolioDesign & Construction Installation & Commissioning Warranty & Post-Warranty

DecommissioningFront-End

Engineering

Detail

Engineering

Equipment

Selection &

Procurement Construction Commissioning Start-Up Operation

Life Time

Extensions

Installation & Commissioning

Repairs & Interventions

Training

Evolution Services

Remote Services

Preventive Maintenance

Condition Monitoring

Advanced Industry Services

Upgrades & Retrofits

Spare Parts

Consulting (Energy Efficiency, Productivity, Reliability, Safety)Consulting (Energy Efficiency, Productivity, Reliability, Safety)

Full Service (Maintenance Outsourcing)Full Service (Maintenance Outsourcing)

Optimization Services


© ABB Group

September 24, 2012 | Slide 11

ServicePro

Maintenance Management: Higher equipment and process availability, more production and improved quality as service practices are applied proactively rather than reactively.

Parts Management: Lower costs as parts are ordered on longer lead times; higher productivity as equipment and processes do not wait for parts arrival.

Report Management: Document contract compliance, assess service effectiveness, ensure overall system and process performance.

Optimization Management: Keeps plant

running; maximizes system performance; optimizes process performance; delivers operational excellence

Contract Management: Better budgeting; more knowledgeable resource management; service visibility to help decide which operation is most effective.

Activity Distribution

35%

20%

10%

10%

20%

5%

Optimal Service Delivery Distribution

Preventive

Support

Administration

Scheduled corrective

Optimization

Unscheduled corrective

Service Provider

• ABB

• Customer

• Not done


ServicePro Usage

Sites Registered 2621

Countries Installed 45

Users Registered 1600

Work Orders Completed 1,000,000+

ABB ServicePro product

management is available to

review customer data remotely

and help troubleshoot issues at

no additional cost.

Completed Work Orders By Month for All Countries

Service Coverage: Global View

© ABB Group

Service Coverage: North America View

© ABB Group

© ABB / PA / Control Systems

September 24, 2012 | Slide 15

ServicePro

SYNC

Factory Global Users

Central Database

(Service Activity) Time

Contract

Manager

SAP

Library

(Parts)

BizTalk

Service Activity Work Order Types:

SP - Preventive Maintenance

SC - Corrective Maintenance – Unscheduled

SC - Maintenance – Scheduled

SV - Optimization: Diagnostic, Implementation

SV - Support

SA (NP) - Misc: Overhead, On call, non

scheduled, travel

ServicePro Modules

Contract Management

Maintenance Management

Parts Management

Report Management

Optimization Management

Contract Manager

Sales Support

Regional Reports

Department Reports

Site Reports

Global Reports

Statistics

Support

Preventive Maintenance Practices

Part List Assembly/sub assembly

Criticality

Life Cycle Status:A,L,C,O

Repair Kits

MTBF

Country Specific


Maintenance Management schedules work orders

Service items

Resource & time

management

Due dates

Tasks

Production impact

ServicePro for iOS – Efficiency Enabled

iPhone Mobility

Synchronization with local and central data base

User login/Site selection

Work order selection and completion

Add and edit work orders, limited to most used types

Add time entries

QR code

Tagging site configuration entries

Work order selection

Associative

Mobile service coverage application

iPad App

NEW in 2013



Parts Management

A = Active

C = Classic

L = Legacy

O = Obsolete

Life Cycle Management

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

1 2 3 4 5 6 7

Years

Lif

e C

ycle Obsolete

Limited

classic

Active

Track System lifecycles

High Risk Medium Risk

Low Risk

Rank inventory risk

Failure Failure

Replace before failure Replace before failure

System

Part Kit

Schedule replacement kits based

on mean time between failures

Define

recommended

spares

Failure Mode Monitoring



Report Management delivers info for decision-making


Control Utilization Overview

Control Utilization 0 100

Product Variability

Hi Variability

Lo Variability Target

Avoid

ABB Systems improve production and quality. When the

controls are not utilized, that is an indication of a problem.


The Challenge: Information Overload Finding a needle in a haystack

Few

Many

Represents one unit

Note: 300 units are shown

here. This is a small area of

an industrial process.

Few units

Not difficult to find issues.

Many units

Much harder to find

issues.

Time to find with simple

tools is not practical.

Avoiding false positives is

essential



Diagnose Implement Sustain

Performance

Potential

System

Application

Process

Time

Optimization Services improves ABB value to customer




Performance

Potential

System

Application

Process

Time


1) Fingerprint

1

Gap

Goal Present

Diagnose




Performance

Potential

System

Application

Process

Time


1) Fingerprint

1

Gap

Goal Present

Diagnose

2) HandsOn

2

Implement

1 2 3




Performance

Potential

System

Application

Process

Time

Optimization Services improves ABB value to customer Sustain

Periodic Evaluation Periods

3) Scan

3 Manage

Performance

Gap

1) Fingerprint

1

Gap

Goal Present

Diagnose

2) HandsOn

2

Implement

1 2 3




Performance

Potential

System

Application

Process

Time

Optimization Services improves ABB value to customer Sustain

Periodic Evaluation Periods

3) Scan

3 Manage

Performance

Gap

1) Fingerprint

1

Gap

Goal Present

Diagnose

2) HandsOn

2

Implement

1 2 3

4

4) Track

Alert





ABB Optimization Services: packaged deliverables for control systems and customer processes

Common Industrial Services :

Boiler

Alarm

System

Loop Analysis

Transition Analysis

Batch Analysis

Tuning



ABB Fingerprint finds gaps, develops customer ROI

Data Collection/Testing

12 to 24 hours at 5-second data

Controller parameters

Customer interview: process area and

loop criticality definitions.

Performance Evaluation

Standard Methodology

Analysis Expertise

Performance Visualization

Report

Gap Analysis

ROI Forecast

Action Plan

Benchmark ROI Findings Plan

OPC

Collection

Tools

People

Process

Tools

1 Report

Action

Problem

Interpret

Analyze

View

Get

Technical Tool Development List


Data collectors

Data logger

Alarm logger

QCS history tool

Security logger

High speed data driver

Consulting tools

Profile analyzer

LoopTune

Signal analyzer

Loop simulator

KPI / Aggregate analyzers

Control utilization

VPA analyzer

KPI analyzer

Interface tools

Harmony direct

Harmony explorer

AGP400

MOD direct

Management

Data manager

ReportPro

Contract manager

Support site

Business tools

ServicePro

ServicePoint

PA KPI Dashboard

Steady state analyzers

Harmony performance analyzer

Loop performance analyzer

Sensor performance analyzer

Dragline analyzer

Shovel analyzer

MOD300 analyzer

800xA analyzer

Security analyzer

Other

Alarm analyzer

Transition analyzer

Sequence analyzer

Hoist

Oil&Gas / Chemical / pharma

Pulp & paper

Cold rolling mill


Increased

performance

1

Service

2

3

Diagnose

(Fingerprints)

Implement

(HandsOn)

Sustain

(Scan/Track)


ABB implements system & process improvements

Goal: Improve current performance level

Scope based on Diagnose phase

Focused, scheduled activities

Proven practices

ABB-managed improvement program

Solution categories: Hardware

Operations

Tuning

Application

Process

2

Proactive and collaborative



ABB dramatically improved this control loop

Original Tuning

(Unstable)

New Tuning

Manual Operation

Much

Better

2


ABB Boiler Optimization helped find fuel savings

Fuel Savings

100KUSD Saving

Boiler O2 vs. Load

1 Hour Averages

2

ServicePort Performance Channels

Select what services you want:

Equipment Channels diagnose

and facilitate services for ABB

products (control systems etc)

Example: Harmony

Performance

Process Channels diagnose and

improve production processes

Example: Loop Performance

Industry Channels diagnose and

improve industry-specific

equipment and processes

Example: Mine Hoist

Performance


Why ServicePort?


0

10

20

30

40

50

60

70

80

90

100

Eq

uip

ment

Perf

orm

ance

Time

Traditional system approach

Performance

peaks, then

degrades

0

10

20

30

40

50

60

70

80

90

100

Serv

ice P

erf

orm

ance

Time

Traditional service approach

Performance

depends on

availability

Why ServicePort?


ServicePort

0

10

20

30

40

50

60

70

80

90

100

Eq

uip

ment

Perf

orm

ance

Time

Traditional system approach

Performance

peaks, then

degrades

0

10

20

30

40

50

60

70

80

90

100

Serv

ice P

erf

orm

ance

Time

Traditional service approach

Performance

depends on

availability

0

20

40

60

80

100

Overa

ll P

erf

orm

ance

Time

Ensures consistent

performance

improvement

Why ServicePort?


ServicePort

0

20

40

60

80

100

Overa

ll P

erf

orm

ance

Time

Ensures consistent

performance

improvement

Fingerprint

On-Site

Performance Services reactive to proactive

Event-driven action

Scheduling Collection Analysis Resolution

Collection Analysis Resolution

Collection Analysis


KPI

Trending

On Site

Remote On Site

On Site

Data Pool

Remote

On Site

Data Pool

Resolution

On Site

On Site

On Site


Condition

Monitoring

On Site

Data Pool Remote

Event Trigger

On Site

Serv

iceP

ort

Reactive

Proactive

Short Lead time

No Lead time

Scan Services

Track Services

Periodic Remote

Enabled Service

Modules

ABB ServicePort

Secure, remote service delivery platform

ABB ServicePort is a service delivery platform through

which customers and ABB experts can securely access:

Diagnostic services

Improvement services

Performance-sustaining services

ServicePort lets you subscribe to channels of different

high-value services that are most important to you

If you want to ensure equipment runs well or optimize

processes, you can benefit from the latest diagnostic

and improvement services – when you want them

ServicePort can also be a valuable on-site resource for

visiting engineers to perform advanced services


New – Introduced to Market this Year

ABB ServicePort Improves access to experts, reduces customer costs




ServicePort: Scan/Track KPIs to ensure improvement

1

KP

I T

rack

ing

Total

CD

RES

MDL

Q1 Q2 Q3 Q4

Delivery Schedule

Production

increase!

Variability

decrease!

Continuous

Improvement

3

-42

Optimization Summary – Achieved ROI

Total Optimization Savings : $1.2M – $1.4M

PM1

Grade change time improvement:

14.3 to 16.6 minutes: ROI $445K - $526K (2260 – 2660 Tons)

PM2

Grade change time improvement:

9.5 to 10.0 minutes: $365K - $387K (2080 – 2200 Tons)

MD weight and moisture variability reduction improvement

Weight target shift: $232K - $287K, (488 – 604 Tons)

Moisture target shift: $74K - $147K, (155 – 309 Tons)

PM3

Recovery Time: ROI $65K - $86K (1300 – 1725 Tons)

Advanced services: increasing customer loyalty and expanding service scope

Example: US Corrugated paper, South Carolina, USA

Customer challenge: A QCS performance fingerprint

audit performed after a plant went into self-maintenance

revealed significant opportunity for optimization in the

world’s most eco-friendly paper plant.

ABB solution: Paper machine Fingerprint Plus

optimization services 2x per quarter which eventually

evolved into a remote services contract.

Customer benefits: Enabled increase of output from 280

TPD to 780 TPD. Modular, flexible approach to service as

the needs of customer changed, ability of installed

products to interact with newer products.

ABB benefit: 1st remote services contract in the USA (just

renewed), 1st optimization service contract in the USA.

Products have increased scope of business with customer,

relationship with customer going strong over 17 years.

Customer challenge: A three-line

chemical polymers plant makes

multiple grade changes. Automation

performance has declined as product

line expanded into specialty chemicals.

ABB solution: Loop Performance and

Transition Fingerprints packaged with

Implementation Services for Tuning

and Corrective Action. ServicePort for

sustaining production enhancements.

Customer benefits: Estimates of over

$1Million per year in increased

production and reduced off-spec waste

byproducts.

Site: LA, USA

Industry: Chemical

Issue:

Automation performance declined as

product line expanded

Solution:

Loop Performance Fingerprint

Transition Fingerprint

Implementation Services

ServicePort

Customer Case Study Chemical plant, Louisiana, USA

PA LCS Services ABB’s Vision for Services · Advanced services: increasing customer loyalty and...

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