© ABB Group September 24, 2012 | Slide 1
© ABB Group September 24, 2012 | Slide 1
PA LCS Services State of the art Services for maximizing system and optimizing process performance
© ABB Group September 24, 2012 | Slide 2
…When you can measure what you are
speaking about and express it in
numbers, you know something about it;
When you can not measure it . . . your
knowledge is meager and unsatisfactory.
Lord Kelvin
© ABB Group September 24, 2012 | Slide 3
Global Cumulative Service Activity Totals:
• 1,026,611 Service Hours
• 1,000,374 Service Work Orders
• 2600 Active Sites
• 1600 Service Engineers
© ABB Group September 24, 2012 | Slide 4
Actual ABB Service Evaluation at customer site
Manage Service Activity
Reduce Reactive Services - Don’t run to failure
Proactive
Reactive
© ABB Group September 24, 2012 | Slide 5
© ABB Group September 24, 2012 | Slide 5
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 6
ABB Lifecycle Services customer value drivers
Identify
Value
Packaged Services
Keep
Production
Running
Deliver
Operational
Excellence
Optimize
Processes
Maximize
Systems
Responsive Efficient Standard
Increase
Efficiency Increase Productivity
Reduce Costs
Leverage
Knowledge Apply and Retain
Expertise
Service
Development
Identify
Value Packaged Services
© ABB Group September 24, 2012 | Slide 7
ABB Lifecycle Services customer value drivers
Identify
Value
Packaged Services
Keep
Production
Running
Deliver
Operational
Excellence
Optimize
Processes
Maximize
Systems
Responsive Efficient Standard
Increase
Efficiency Increase Productivity
Reduce Costs
Leverage
Knowledge Apply and Retain
Expertise
Service
Development
Identify Value
Packaged Services
ServicePoint – Customer Value Profile
Keep Production Running
Maximize System Performance
Optimize Process Performance
Deliver Operational Excellence
We help identify key service values and priorities
ServicePoint – Services matched to need
Keep Production Running
Maximize System Performance
Optimize Process Performance
Deliver Operational Excellence
Quickly find the services that match your needs
© ABB Group September 24, 2012 | Slide 11
© ABB Group
September 24, 2012 | Slide 11
ServicePro ABB Products Service Best Practices
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
© ABB Group September 24, 2012 | Slide 12
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
Service Coverage: Local View
© ABB Group We’ve got you covered!
© ABB / PA / Control Systems
September 24, 2012 | Slide 16
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
© ABB Group September 24, 2012 | Slide 17
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
© ABB Group September 24, 2012 | Slide 19
© ABB Group September 24, 2012 | Slide 19
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
© ABB Group September 24, 2012 | Slide 20
© ABB Group September 24, 2012 | Slide 20
Report Management delivers info for decision-making
Optimization Management Improves access to experts, reduces customer costs
© ABB Group September 24, 2012 | Slide 21
© ABB Group September 24, 2012 | Slide 22
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.
© ABB Group September 24, 2012 | Slide 23
ABB ServicePort Finds 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
© ABB Group September 24, 2012 | Slide 24
© ABB Group September 24, 2012 | Slide 24
Diagnose Implement Sustain
Performance
Potential
System
Application
Process
Time
Optimization Services improves ABB value to customer
© ABB Group September 24, 2012 | Slide 25
© ABB Group September 24, 2012 | Slide 25
Diagnose Implement Sustain
Performance
Potential
System
Application
Process
Time
Optimization Services improves ABB value to customer
1) Fingerprint
1
Gap
Goal Present
Diagnose
© ABB Group September 24, 2012 | Slide 26
© ABB Group September 24, 2012 | Slide 26
Diagnose Implement Sustain
Performance
Potential
System
Application
Process
Time
Optimization Services improves ABB value to customer
1) Fingerprint
1
Gap
Goal Present
Diagnose
2) HandsOn
2
Implement
1 2 3
© ABB Group September 24, 2012 | Slide 27
© ABB Group September 24, 2012 | Slide 27
Diagnose Implement Sustain
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
© ABB Group September 24, 2012 | Slide 28
© ABB Group September 24, 2012 | Slide 28
Diagnose Implement Sustain
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 Group September 24, 2012 | Slide 29
© ABB Group September 24, 2012 | Slide 29
© ABB Group September 24, 2012 | Slide 29
© ABB Group September 24, 2012 | Slide 29
ABB Optimization Services: packaged deliverables for control systems and customer processes
Common Industrial Services :
Boiler
Alarm
System
Loop Analysis
Transition Analysis
Batch Analysis
Tuning
Fingerprint
On-Site
Performance Services reactive to proactive
Event-driven action
Scheduling Collection Analysis Resolution
Collection Analysis Resolution
Collection Analysis
Collection Analysis Resolution
KPI
Trending
On Site
Remote On Site
On Site
Data Pool
Remote
On Site
Data Pool
Resolution
On Site
On Site
On Site
Collection Analysis Resolution
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 Group September 24, 2012 | Slide 31
© ABB Group September 24, 2012 | Slide 31
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
© ABB Group September 24, 2012 | Slide 32
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
© ABB Group September 24, 2012 | Slide 33
Increased
performance
1
Service
2
3
Diagnose
(Fingerprints)
Implement
(HandsOn)
Sustain
(Scan/Track)
© ABB Group September 24, 2012 | Slide 33
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 Group September 24, 2012 | Slide 34
© ABB Group September 24, 2012 | Slide 34
ABB dramatically improved this control loop
Original Tuning
(Unstable)
New Tuning
Manual Operation
Much
Better
2
© ABB Group September 24, 2012 | Slide 35
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
© ABB Group September 24, 2012 | Slide 36
Why ServicePort?
© ABB Group September 24, 2012 | Slide 37
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?
© ABB Group September 24, 2012 | Slide 38
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?
© ABB Group September 24, 2012 | Slide 39
ServicePort
0
20
40
60
80
100
Overa
ll P
erf
orm
ance
Time
Ensures consistent
performance
improvement
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
© ABB Group September 24, 2012 | Slide 40
New – Introduced to Market 9/10/12 (Yesterday)
ABB ServicePort Improves access to experts, reduces customer costs
© ABB Group September 24, 2012 | Slide 41
© ABB Group September 24, 2012 | Slide 42
© ABB Group September 24, 2012 | Slide 42
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
ServicePort -- Scan
Much Faster presentation of information.
Summary of KPI’s per analysis session
Example service report (Scan) Channels produce reports that guide customer actions
Statistical evaluation of historical KPIs performed twice a year
Ensures stability of KPIs
Reduces risk of false positives
Keep up to date with process
Crucial to ensure continuous improvement
-45
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: Papermachine 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
Optimization Service Solutions: Performance Engine
Process
Monitor
On-Demand Audit
ServicePort
Support Line Fingerprint
Packaged Diagnostic Services:
Performance Engine built on proven
ABB Service Technology.
Improve
ABB Systems and Service
© ABB Group September 24, 2012 | Slide 49
Production Quality
Cost to Produce
Process
If ABB is not on, then it is broke!
Sensors Frames Actuators OCS Application Displays Controls
Drives Electrification Power
Extend LifeCycle
ServicePoint ServicePort
ServicePro ServiceApps
© ABB Group September 24, 2012 | Slide 50
© ABB Group September 24, 2012 | Slide 50
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