Service and maintenance risk mitigation guide. Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. GMSG-SP007A-EN-P

Transcription

1 Service and maintenance risk mitigation guide Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. GMSG-SP007A-EN-P

2 An ARC Advisory Group report shows that the average impact of unscheduled downtime in the process industries is $20 billion, or almost 5% of production. 1 Rigorous production demands and the pace of change intensify the pressures on people and equipment. In terms of manufacturing models, products don t have to be made in the same region or country any more. The Boeing 787 Dreamliner, for example, is manufactured with components from 287 suppliers across 22 countries, creating a complex global network that simply wouldn t have been viable a couple of decades ago. 2 Where staffing is concerned, evolving technologies place relentless demands on people. An article in Plant Services magazine highlights how a typical maintenance technician working ten years ago, was expected to read and understand about 500 pages of technical information, written at eighth-grade level, to maintain plant equipment. Today, that technician must read and understand 5,000 pages written at undergraduate or higher level. 3 And with the pressures of delivering against constant change, you re still being expected to produce more for less. Customers demand not just more output, but more flexibility. All the while, eyes constantly scan budgets and bottom lines, looking for consistency as well as profitability. Integrated systems bring the benefits of efficiency, but magnify the implications of issues in any one element of the production process. To complement our progressive automation solutions, Assurance TM Integrated Support helps you to mitigate the risks of downtime, to ensure a reliable, available support network in the event of an incident. It provides financial predictability, with one flat fee for a comprehensive service agreement and no additional fees for repair parts or on-site labor. 2

3 Overcoming productivity challenges Research undertaken in 2010 found that the average manufacturer loses more than $196,000 per year from systems outages. 4 These unexpected problems that cause downtime are more of a threat than an inconvenience. Customers have demanding expectations, and delays are costly in all sorts of ways. You could never hope to eliminate the number of downtime incidents, but by taking a proactive approach towards your downtime response, you can avoid much of the impact and return your operation to normal productivity quickly and efficiently. Assurance Integrated Support includes: l Support right there when you need it to reduce the impact of downtime l Guaranteed response times to help streamline the recovery process and ensure problems are overcome swiftly l Fixed billing to support budget planning l Equipment audits and health checks to gain insight into the potential risks of an incident Reduce the impact of incidents In the event of a problem, you need to know that you have access to a team that can take on and resolve the problem as quickly and efficiently as possible, leaving you free to concentrate on adapting resources to meet existing production goals. With an Assurance Integrated Support agreement, you ll have a guaranteed response in place, giving you more control and reducing your exposure. Guaranteed response time When downtime hits, you have to know that the support you call in will be there when needed. Assurance Integrated Support is activated with one call from you, eliminating the uncertainty surrounding your problem, and helping you to deal with queries from internal stakeholders and customers. Accurately forecast expenses Unexpected equipment and service costs allied with additional training requirements can upset your budget plans. Our fixed billing arrangement and annual fee helps you put together an accurate, predictable annual budget. Stop the impact spreading down the line Downtime in one area can affect your entire plant. We help to minimize the potential for problems to arise with comprehensive equipment and health checks as an integral part of your Assurance Integrated Support agreement. 3

4 The pros and cons of advancing technologies The cost of 1 million transistors has steadily dropped from over $222 in 1992 to $0.13 in Scale isn t necessarily the differentiator these days. Now, the focus is on a bold, innovative approach that invests in new technologies and builds in the flexibility needed to fulfill diverse, shorter-run orders. System automation brings massive benefits to the process industry today, but it also carries a certain degree of risk. Although integration is the logical goal, it means that a problem in one area can affect the whole plant. Clearly it pays to have a plan in place to prepare for this. With Assurance Integrated Support you get: l Support across every technology in your system l External specialists who know your system so you don t have to brief anyone before they start work l Guaranteed spare parts inventory so you can get back on track quickly Support across your entire system Support is available for every element of your architecture including drives, motion control, networking, controllers and HMI. Your Assurance Integrated Support engineer will have the knowledge of your system to address problems quickly, and spare parts are guaranteed to be in stock when you need them. Reduce the time spent on identifying the problem With sophisticated, integrated technologies, it s sometimes hard to pinpoint the source of trouble. Assurance Integrated Support ensures that you have experts on-hand immediately to identify and correct the problem quickly. Spares available on-demand It takes time and money to keep a comprehensive spares inventory in stock, but you need to know that parts are available should you require them. With Assurance Integrated Support, getting replacement parts is simple and fast. As a customer, you have access to $100M in spare parts, ready for immediate shipping, saving you time and money. 4

5 Don t let the skills gap impact on your operations or productivity With around ten million jobs in manufacturing that can t be filled due to the growing skills gap 6, the management of your staff and their varying skills, knowledge and experience is key to efficient production. It s estimated that only three to seven new employees replace every ten retiring maintenance workers, creating a significant intelligence gap. 7 With this decline in numbers, specialist knowledge is difficult to come across and expensive, while more general support won t be able to support today s advanced equipment. Assurance Integrated Support helps you to address the skills gap: l Direct access to external support l Expert field engineers available 24/7 l Match the skills available with the projects or issues in hand l Scalable support and increased predictability 24/7 access to the specialist support you need Direct access to qualified experts help you to maintain and manage your plant at a predictable cost. Assurance Integrated Support helps you to meet fluctuating demand for support. Getting the right people onto the right jobs Our support program enables you to concentrate existing staff on their tasks, while bringing in people you can trust to overcome your complex problem. You can eliminate the time spent searching for qualified people, reduce the risks of a bad hire and cut out the time lag between hiring date and training completion. Keep existing intelligence in-house Assurance Integrated Support means you can keep the staff you already employ and help them to broaden their knowledge. With web-enabled information and valuable remote training, you can increase the level of in-house expertise and establish a database to maintain native intelligence. Support you can scale up or down to meet your needs Over-staffing is expensive and needs much administrative input, but to be under-resourced is an unnecessary risk to take. With Assurance Integrated Support, you can call on additional, specialist input when the need arises, with just one phone call. 1 ARC Advisory Group, MAC Approach Continues to Pay Dividends for Owner-Operators, July Airframer.com. (2011) Boeing 787 Dreamliner Program Suppliers Report 3 articles/2006/209.html /01/lean-manufacturing-skinny-facts 5 The Future of Manufacturing Opportunities to drive economic growth, World Economic Forum 6 Source: The future of manufacturing opportunities to drive economic growth, World Economic Forum 7 Plant Services magazine Source tbc 5