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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
May 22, 2018 | Slide 2
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 Group
May 22, 2018 | Slide 3
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 Group
May 22, 2018 | Slide 4
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 Group
May 22, 2018 | Slide 5
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 Group
May 22, 2018 | Slide 6
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 Group
May 22, 2018 | Slide 7
1. OEE assessment
Evaluates process and assets

Financial Mgr. Maintenance Mgr. Production Mgr. Quality Mgr.


Equipment Production Quality
Availability (A) Rate (P) Factor (Q)

People Product Material


HR Manager Supply Manager
Profit
Plant VP/Manager

 Applies proven analysis methodology


 Measures relationships
 Equipment availability

 Production efficiency

 Rate of quality

 Uncovers potential benefits

© ABB Group
May 22, 2018 | Slide 8
2. Maintenance Performance Assessment
Includes maintenance cost

Financial Mgr. Maintenance Mgr. Production Mgr. Quality Mgr.

People Product Material


HR Manager Supply Manager
Profit
Plant VP/Manager

Utilization Methodology Performance


 Time spent waiting • Business processes • Skills
 Craft coordination • Planning • Training
 Availability of drawings • Special tools • Job interruptions
 Craft flexibility • Scheduling • Supervision
 Parts availability • Standard jobs library • Morale
 Level of rework • Rebuild procedures • Labor issues
• Precision
maintenance

© ABB Group
May 22, 2018 | Slide 9
3. Reliability Culture Assessment:
Roles and responsibilities, reliability training, failure analysis

Financial Mgr. Maintenance Mgr. Production Mgr. Quality Mgr.

People Product Material


HR Manager Supply Manager
Profit
Plant VP/Manager

 Review maintenance practices Review organizational structure


and maintenance culture (job responsibilities, ratios)
(planning and scheduling
effectiveness) Identify maintenance and
 Understand plant reliability reliability gaps
culture
 Identify perceived strengths
and improvement
opportunities

© ABB Group
May 22, 2018 | Slide 10
Primary Activities

Information Gathering Analysis Delivery


(On- and off-site) (off-site) (on-site)

1 Week on-site 1 Week off-site  Present Reports


 Pre-arrival data Develop Metric Charts
collection packet Draw Cost/Structure
 Collect Data on-site Conclusions from Metrics
 Validate Data Finalize OEE Calculations
 Confirm information Develop OEE Waterfall
understanding with Develop Business Case with
Customer ABB Account Personnel
Develop Findings Presentation

Complete Executive Summary

© ABB Group
May 22, 2018 | Slide 11
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 Group
May 22, 2018 | Slide 12
OEE Overview

Total Available Production Time

Non-
Planning
Planned production time production
time
Factor (Pf)

Availability Equipment failure Availability


Gross operating time Losses Set-up and adjustments Factor (A)

Speed Idling and minor stoppages Performance


Net operating time Losses Factor (P)
Reduced speed

Valuable Quality Defects in process Quality


operating time Losses Start-up losses Factor (Q)

OEE Availability Performance Quality Valuable operating time


% = factor X factor X factor =
(A) (P) (Q) Planned production time

© ABB Group
May 22, 2018 | Slide 13
Sample Deliverable
OEE Waterfall – PM 1: OEE = 75%

PM 1: OEE = 75 %
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000

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
May 22, 2018 | Slide 14
Maintenance Performance Example:

20
Maintenance Cost is tied to:
World class  Effectiveness of maintenance
1.5% – 2.0%
 Skill level and quality of
Maintenance cost as % of facility replacement cost

knowledge of personnel
14  Asset type
Your  % of unplanned maintenance
12
facility
 % of predictive maintenance
10

Example PM#1 - Vibration


8
detects bearing wear
6  Proactive Maintenance -
Bearing is changed (cost
4 $5,000)
2
 Reactive Maintenance -
Bearing is not changed,
0 Machine fails (cost $100,000)
5 10 15 20 25 30 35 40 45

Facility number

© ABB Group
May 22, 2018 | Slide 15
Areas evaluated with fingerprint

Reliability Culture Areas


10

8
High
7
dB Avg
Site Score
6
Low
5

RR RM PM ML OS SS PAP CE PA