ABB ServicePro 4.0 Service Management System

Transcription

1 ABB ServicePro 4.0 Service Management System Presented by Paul Radcliffe PS Service June 6, 2014 Slide 1

2 Questions customers ask How successful is my maintenance program? - Am I performing the right PM tasks at the right frequency? - Is my PM program preventing unscheduled process downtime or equipment failures? How much more money could I make or save by improving my maintenance? - What is the revenue potential if production is increase or downtime reduced? - What is the savings potential by reducing equipment failures and parts costs? What kind of tools or services could help me here? - Do I have processes and systems in place to track my maintenance activities?

3 Work Orders Common service problem: reactive vs proactive Dangerous Service Method Reactive Services Managed Service Method Proactive Services Improper balance Expensive Unpredictable Something will break Customer must define good Extended downtime Rush parts orders Schedule correction Unplanned downtime Proper Balance Service tailored to need Predictable Fix before failure Higher reliability Reduce downtime Normal parts ordering Scheduled service Planned downtime

4 The new ServicePro 4.0 Service Management System What it is Automation and process best service practices for lifecycle management A service tool that provides global best service practices and lifecycle support information recommended by ABB Historian for maintenance activities and parts information Spare parts management tool Lifecycle management tool Maintenance program measurement and reporting tool ABB Service Management System Results (steel mill) June 6, 2014 Slide 4

5 The new ServicePro 4.0 Service Management System What it offers Automation and process best service practices for lifecycle management Manages service compliance Proactively schedules maintenance Aligns parts needs with service Helps optimize system and process performance ABB Service Management System Results (steel mill) Generates reports that help improve availability, increase production and raise quality June 6, 2014 Slide 5

6 Contains libraries of products & process best practices Lifecycle status Proactive service procedures Spare parts recommendations Inventory analysis Schedules for maintenance Optimization schedules Etc June 6, 2014 Slide 6

7 Service Pro 4.0 Benefits KPI benchmarking of maintenance program Reduction of unplanned maintenance cost Improved reliability and productivity Lifecycle cost forecasting Spare parts cost management Reduced lifecycle cost June 6, 2014 Slide 7

8 ServicePro 4.0 Benefits/Uses: Customer Engineers Faster synchronization Multiple site synchronization versus one site at a time Better navigation: see all your sites on one navigation bar Time entry views now on single window for multi-site viewing Improved work orders grouping, by type or system Improved system configuration so grouping of items to be performed in single process or system area can be accomplished at setup June 6, 2014 Slide 8

9 ServicePro 4.0 Benefits/Uses: Customer managers Contract Manager module, added reporting June 6, 2014 Slide 9 Area or regional time reporting for engineers Area or Regional time reporting for customers Overview of labour completed vs labour pending Technology-specific resource planning Contract estimator to estimate preventive maintenance needs for a configured system Lifecycle estimator across a region or group of customers Area or regional parts information management

10 ServicePro 4.0 Benefits/Uses: Corporate Technology Review corporate spare parts inventory Review corporate systems lifecycle status Corporate-wide lifecycle management Maintenance spend by technology (parts and labor) Contract or labour estimator to determine suggested parts and labor required at sites Benchmarking site maintenance programs Corrective maintenance history helps determine training and support needs June 6, 2014 Slide 10

11 ServicePro 4.0 synchronizes best practices ABB / PA / Control Systems June 6, 2014 Slide 11

12 ServicePro 4.0 synchronizes best practices: site Global synchronization of ServicePro libraries ensures that users have the latest information available for parts, service best practices and system lifecycle information ABB / PA / Control Systems June 6, 2014 Slide 12

13 ServicePro 4.0 synchronizes best practices: site & ABB Global sync also enables sharing of site data. This data can be shared within ABB to allow product and service improvements Enables Sharing of Historical site maintenance data Historical site reliability data Lifecycle information Parts inventory and spare parts usage ABB / PA / Control Systems June 6, 2014 Slide 13

14 ServicePro 4.0 synchronizes best practices: enterprise or across your enterprise, allowing identification of best practices to improve operational excellence. Using Global sync, A maintenance manager can benchmark site to site reliability practices A technology manager can assess the lifecycle status of the enterprise installed base ABB can develop a lifecycle plan for site by site or on the enterprise level ABB / PA / Control Systems June 6, 2014 Slide 14

15 and ServicePro syncs them so all sites can benefit Sites Registered 4141 Countries Installed 59 Users Registered 1761 Work Orders Completed 1,000,000+ 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 June 6, 2014 Slide 15

16 ABB plant reliability mini-audit: how do you stack up? Questions June 6, 2014 Slide 16 Worldclass What percent of equipment have Preventive Maintenance tasks? >80% What percent of PM tasks are benchmarked best practices? >70% What is the percent of completed work orders that are PM? >50% What is the percent of completed work orders that are emergency? <5% What is the percent of working time service people are scheduled? >80% What is the percent of rework by service people? <5% What is the percent of overtime hours is worked on service? <1% What is the percent of availability for production processes? >95% What is the percent of emergency parts purchase orders? <2% What is the percent of on-time delivery for purchased parts? >97% What is the percent of inventory accuracy of spare parts? >95% What is the percent of maintenance parts stockouts? <3% What percent of storeroom items show no issue in last 3 years? <10% What percent of system or process improvements are scheduled? >50% Benchmarks are from ABB Reliability Consulting and represent a compilation of various process and manufacturing industries You

17 ServicePro 4.0 modules improve & sustain performance Contract Management: Helps manage service resources according to contract, helping identify weak performance areas, comparing service across sites etc Parts Management: Tracks and manages parts related to equipment being serviced, including lifecycle status, parts kitting, when to order parts etc. Maintenance Management: Collects and deploys best service practices, guiding planning, scheduling and execution. June 6, 2014 Slide 17 ServicePro 4.0 Optimization Management: Schedules ABB Optimization Services to ensure that system and process improvements are sustained and enhanced. Report Management: Configurable reporting provides visibility and accountability needed to meet customer and ABB management requirements.

18 ServicePro 4.0 module delivers financial benefits Contract Management: Better budgeting; more knowledgeable resource management; service visibility to help decide which operation is most effective. Parts Management: Lower costs as parts are ordered on longer lead times; higher productivity as equipment and processes do not wait for parts arrival. Maintenance Management: Higher equipment and process availability, more production and improved quality as service practices are applied proactively rather than reactively. June 6, 2014 Slide 18 ServicePro 4.0 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.

19 ServicePro Mobile enables fast accurate service Scan QR Code Scan the QR tag on a piece of equipment to automatically see what service is required. Reduce time required for service activity entry Increase the accuracy of data entry. June 6, 2014 Slide 19

20 Maintenance Management schedules work orders Service items Due dates Resource & time management Tasks Production impact June 6, 2014 Slide 20

21 Maintenance Management manages resources Engineer Hours worked ERP interface New! Work order browser June 6, 2014 Slide 21

22 Parts Management ranks risk to prioritize purchasing High Risk Gap Medium Risk Gap Low Risk Gap June 6, 2014 Slide 22

23 Life Cycle Yr1 Yr2 Yr3 Yr4 Yr5 Yr6 Yr7 Yr8 Yr9 Yr10 Parts Management tracks parts lifecycles to plan better Item Obsolescence Created with dynamic lifecycle information from master library Real time notification of lifecycle status changes A = Active C = Classic L = Legacy O = Obsolete Life Cycle Management 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Obsolete Limited classic Active June 6, 2014 Slide 23 Years

24 Case: ABB Preventive Maintenance System Customer Paper Mill PM Performance Impact on Equipment Repair Requirements TOTAL REPAIR HOURS 4,500 % PM COMPLETION 4,000 3,500 3,000 2,500 2,000 1,500 1, REPORTING PERIODS Routine Repair Hours 2,554 4,109 3,565 2,042 2,155 1,955 Emergency Repair Hours 1,298 1,541 1,323 1,138 1, % PM Completion 74% 77% 86% 86% 88% 91% 100% 95% 90% 85% 80% 75% 70% 65% 60% 55% 50% % PM Completion Planned Repair Hours Unplanned (Emerg) Repair Hours June 6, 2014 Slide 24

25 Press Scrap % Case: ABB Preventive Maintenance System Customer Paper Converting Percent of Press Scrap versus PM Completion 20% 18% 16% 14% 12% 10% 8% 6% 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% PM Completion % PRESS #1 PRESS #2 PRESS #3 PRESS #4 PM COMPLETION %

26 Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Case: ABB Preventive Maintenance System Customer Steel Mill Reported Hours % PM Completion 700 Planned Repair Hours 500 Unplanned (Emergency) Hours % PM Completion 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% PM Completion 67% 73% 79% 73% 67% 79% 74% 79% 86% 85% 89% 82% 89% 90% Emergency Routine % PM Completion Unplanned (Emergency) Hours Planned Repair Hours

27 PM Completion % Case: ABB Preventive Maintenance System Customer Injection Molding 100% 25 80% 60% 40% 20% WEEKLY AVERAGE REPAIRS 0% PLANT PM COMPLETION WKLY AVG PLANNED REPAIRS WKLY AVG EMERG REPAIRS May thru July 2005

28 ServicePro 4.0 helps drive culture change Current Reactive Changing Discovery Arriving Proactive Synergy Service by instinct: we always do it this way Improvement needed, but there never is time Service relegated to maintenance Lack of management involvement Management commitment to improvement Service is a plantwide responsibility Discipline, rules, processes in place Supervisors train & value all personnel Personnel understand roles, apply knowledge, have same goals Value cooperative efforts, care for self & others Apply best practices Help others conform Controlled empowerment Equal reward distribution for attaining continuous goals Organizational pride Continuous cost reduction and productivity improvement

29 ABB culture change example I must admit that I was VERY skeptical about this program but now I have to say, How did we ever work without it? It is probably the best tool we have and you are just making it even better. I did a monthly report in 15 minutes last month instead of the several hours it used to take. Thanks a lot for the work you have been doing. I just wanted to say it again how much we appreciate what you are doing. Senior field engineer June 6, 2014 Slide 29

30 Customer culture change example Boise Paper Linerboard and Newsprint mill Deridder, Louisiana, USA Identified and resolved recurring equipment problems Real-time data access eliminated need for monthly reporting, improving overall process automation and management efficiency Monitors spare parts use and inventories so mill always knows what parts are needed and when Tracks control system uptime and downtime to identify possible problems Tracks work order completions to ensure overall service efficiency Monitors overtime and other automation service costs to ensure cost control This is a well-written, professional program. I personally have used ServicePro to identify opportunities where ABB can help me further. Ken Whaley, Process Control Superintendent, Boise Deridder

31 Customer culture change example Appleton Paper mill West Carrollton, Ohio, USA mill Easily customizable report capabilities helped customer create concise reports on what s most relevant Data on work order completion and contract hours spent helps manage service scheduling and downtime activities for higher efficiency Work order history helped identify and troubleshoot equipment problem by pinpointing source of the problem with pulp flow positioning motors ServicePro s proactive service approach helped mill move maintenance activities from corrective to preventive, and reduce emergency service calls Mont ServicePro is an integral part of our maintenance program and philosophy. Other companies don t have anything close to it. Bill Levenderis, process engineer, Appleton Paper

32 I have a CMMS; why should I use ServicePro 4.0? Standard Feature ABB Other Ability to sync multi-site information globally to a central database X Compare site activities to those at other internal company sites X Compare site activities to those at other sites globally X Compare time required to support equipment at your site to time required at other sites. X Provide equipment life cycle status information X Part inventory management X X Part condition management X Parts risk assessment and analysis X Part order tracking X X Part repair status X X Site statistics and KPIs monitored by managers so they can quickly address problems X maintenance procedures implemented and ready to use X Extensive reporting package with 50 standard report templates implemented and ready to use X Ability to support internal and external users X X Provided at no cost as part of maintenance service agreement X Additional manpower needed to maintain and manage X New version releases and updates automatically downloaded at no cost to the customer X 100% application functionality in 1-day start-up X Software managed by experts with hands-on experience with systems and customer processes X Initial software licenses, implementation costs and annual fees X

33 ServicePro 4.0 Service Management System summary Best service practices Manages service compliance Proactively schedules maintenance Aligns parts needs with service Helps optimize system and process performance Generates reports that help improve availability, increase production and raise quality ABB Service Management System Results (steel mill) ServicePro 4.0 helps improve production and reduce costs! June 6, 2014 Slide 33

34 ABB / Control PA / Control Systems Systems June 6, 2014 Slide 34