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
April 13, 2015 | Slide 2
Introduction
© ABB Group
April 13, 2015 | Slide 3

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
Benefits
© ABB Group
April 13, 2015 | Slide 4

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
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
April 13, 2015 | 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
April 13, 2015 | 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:


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
PM2
= $31,401
= $67,419
Total for both machines Year 2
= $98,820
Each extra or marginal ton of PM1 availability = $300 ($756/hour)
© ABB Group
April 13, 2015 | Slide 7
1. OEE assessment
Evaluates process and assets
Financial Mgr.
Maintenance Mgr.
Production Mgr.
Equipment
Availability (A)
Production
Rate (P)
People
HR Manager
Product
Profit
Plant VP/Manager



© ABB Group
April 13, 2015 | 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
April 13, 2015 | 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
April 13, 2015 | 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
© ABB Group
April 13, 2015 | Slide 11
Analysis
(off-site)
1 Week off-site
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
April 13, 2015 | 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
Availability
Losses
Gross operating time
Net operating time
Valuable
operating time
OEE
%
© ABB Group
April 13, 2015 | Slide 13
=
Equipment failure
Set-up and adjustments
Speed
Losses
Idling and minor stoppages
Reduced speed
Quality
Losses
Availability
factor
(A)
Planning
Factor (Pf)
Defects in process
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
April 13, 2015 | 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
April 13, 2015 | 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)
Areas evaluated with fingerprint
Reliability Culture Areas
10
9
High
dB Avg
Site Score
Low
8
7
6
5
4
3
2
1
0
RR
RM
PM
ML
OS
SS
PAP
CE
PA