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

Sammy Saba – Marketing and Sales Manager ABB Global Consulting – April 2013

The road to Efficiency and Reliability
ABB Global Consulting and Full Service

ABB Global Consulting
Our 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

ABB Global Consulting
Our portfolio 2/2

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

ABB Full Service
Our portfolio

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 management
Implementation
and EEI Energy Efficiency Feasibility Study on electrical and thermodynamic equipment and
Improvement implementation projects with performance based contract (EPC)

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 Group
April 3, 2013 | Slide 5

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 Group

ABB global approach to Energy Efficiency
A complete process from analysis to implementation
(EN 15900:2010)
Energy Mapping Feasibility Realization
Check-Up Flash Audit Detailed Measure and
PHASE e
Measurement
Study Design of Verification
Analysis of the Areas Analysis of Equipments Solution of Results

Building Utilities
Utilities Building Utilities
Utilities
Edifici Utilities Building Utilities
Utilities
AREA
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 Audit
OUTPUT 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 Group
April 2012 | Slide 7

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 Group

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 Group

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 Group

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 Group

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 Group

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 Group

Roadmap 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 Group

Mutual Commitment
Commitment
Commitment
Mutual

Mutual


Agreement
• Assessment

and

Project
definition

© ABB Group

Design
Commitment
Commitment
Mutual

Mutual



Module 1
• As is analysis

• Strategy
definition

• Measurement
system
definition and
implementat.

• Reliability
analysis and
Implementat.

© ABB Group

Implementation
Commitment
Commitment
Mutual

Mutual



Module 2
• Computerized
Maintenance
Management
System Impl.

Module 3

Module 4

© ABB Group

Implementation
Commitment
Commitment
Mutual

Mutual



Module 5

Module 6

© ABB Group

Follow-up – Coaching and training on the job
Commitment
Commitment
Mutual

Mutual


MPI (Maintenance & Productivity Implementation) + EEI MMS / TAM EPM /AMF/FS/O&M

Module 8

© ABB Group

Maintenance Management & Supervision
Commitment
Commitment
Mutual

Mutual



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 Group

Performance Based Agreements
Commitment
Commitment
Mutual

Mutual



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 Group

Software and Application Tools

Commitment
Commitment
Mutual

Mutual


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 Group

Web-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 Group

Contacts

FOR FURTHER QUESTIONS
PLEASE CONTACT:

e-mail: ABB.fullservice@it.abb.com

e-mail: consulting.italy@it.abb.com

© ABB Group
July 2nd 2012| Slide 26

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

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

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