abb industrial maintenance
TRANSCRIPT
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March 22 2011, Pertti Weissenfelt
ABB Full Service
Industrial Viewpoint
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 1
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Table of Contents
What is Industrial Maintenance Service?
Maintenance Service keep cost focus but get
back to production factors Outsourcing evolving in industrial maintenance
What is eneral and what is industr s ecific
Structuring maintenance services industrialviewpoint
Industy specific maintenance offering an
example Summary
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 3 ABB GroupSeptember 1, 2011 | Slide 3
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What is Industrial Maintenance Service?
refers to the repair and upkeep of
the total industrial plant consisting,machines and technology used forproduction.
According to this wide variety ofdifferent kind of technology andequipment, industrial maintenanceec n c ans nee o e mu -
skilled individuals, proficient in
many tasks and to know the
maintaining extremely well.
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 4
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Key Objectives of Asset Performance Management
Smart Information
Asset Performance
Operations Mainten-Mana e
Improve
ance
Improve
CriticalIssues and
Constraints
Utilization
Availability
Sustainabili ty Stewardship
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 5
Source: Asset Performance Management for Process IndustriesARC Strategies, August 2010
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What drives our businesses?Industrial manufacturing, Capex, commodity production
Forecast suggestsindustrial production
World GDP and industrial production growthSource: Global Insight; Nov 2010
GDPIndustrial
Forecastgrowth will deceleratetowards next year.
Commodity prices
4
6
20
30
growth %
WorldGDP
productiongrowth %
Industrialproduction
China
con nue e r upwartrend, but still are belowpre-crisis level.
Oil rice WTI avera ed
-2
0
-10
0
Industrialproduction
US
IndustrialproductionEurozone
$80 a barrel during last 3months; growth reflectedrenewed investor appetitefor risk, consum tion rise,
- -
08
Q1
08
Q2
08
Q3
08
Q4
09
Q1
09
Q2
09
Q3
09
Q4
10
Q1
10
Q2
10
Q3
10
Q4
11
Q1
11
Q2
11
Q3
11
Q4
Commodity pricesindexed, Jul08=100; source: GF-SCM; LME; EIA; MetalBulletin; Nov 2010
weakness of US dollar.
Copper price has nearlyreached pre-crisis level,
100
125
Iron OreAluminum
CopperPre-crisis level
measures and restocking;China and emerging Asiamainly driving the growth.25
50
08
08
09
09
09
09
10
10
10
10
SteelCrude oil (WTI)
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 6 ABB GroupSeptember 1, 2011 | Slide 6
Jul
Oct
Ja
n
Apr
Jul
Oct
Ja
n
Apr
Jul
Oct
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The focus - Primary Drivers for maintenance
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 7
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Outsourcing evolving in industrial maintenance
The cost of Industrial Maintenance in Europe wil l be growing1,5% per annum unti l 2015.
Mainentenance outsourcing is estimated to increase from the
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 9
Source: FIM StudieAlixPartners 2008
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Business Models of Industrial Maintenance Service
Maintenance providers cri tical task is to select the businessmodel and balance between:
.
2. Maintenance providers own strategy
1. Industr ial technological and system know-how
2. Industry process know-how
.
4. Own background
E.g. ABB Industrial Service main categories
Life-cycle services
ABB Full Service
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 10
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Example of maintenance Offering
1. Complying with HSEregulations at minimum
completedagreementsworldwide
Revenues 2009
Energy
Cost Savings
Indirect
Benefits
nefit
sEnergy
Cost Savings
Indirect
Benefits
nefit
s
. mprov ng p an anfinancial performance
3. Managing maintenance
5,500+ directserviceprofessionals
Delivery in moreMaintenance
Plant
Performance
Benefits
Savings/Be
Maintenance
Plant
Performance
Benefits
Savings/Be
4. Increasing reliability andlife-time of processe ui mentGlobally supported
an coun r esCost Savings
Year 1 Year 2 Year 3 Year 4 Year 5
Cost Savings
Year 1 Year 2 Year 3 Year 4 Year 5
5. Managing change and
creating a service culture
ong- erm, per ormance-based agreements in whichABB commits to maintain
and improve the. and knowledge of ABBsglobal network
performance, energy
efficiency and reliabili ty foran entire facility with
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 11 ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 11
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What is general and what is industry specific
70% of all maintenance is seen as common practices in all industries
e res s n us ry spec c as or examp e n u p aper n us ry:
Safety at work
Process knowledge, Trouble shooting, Optimization
Quality requirements for the final product for customers
Material technology especially in pulp mill equipment
o erv ce an gr n ng
Quality Control System Service
Web Inspection System Service Men
Drives
Hydraulics Input Output
ater a
Machine
Method
ost
Quality
Delivery
on on mon or ng
Lubrication
Industr -s ecific
15% 15% 70%
Common PracticesSite -s ecific
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 12
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Structuring maintenance services industrial viewpoint
organization models are structuredaccording to the production
processes of the industry In Pulp and Paper the structure
usually separates the differentdepartments like pulp production,
ower lant a er machines and
converting as their own maintenanceareas. That is because of thecomplexity of the mills and machinery
Menindustry.
In addition to these there usually is acommon services department which is
Material
Machine
Method
Cost
Quality
Delivery
getting smaller and smaller as theseservices are today done more by localsubcontractors.
15% 15% 70%
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 13
Industry -specific Common PracticesSite -specific
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Industrial maintenance offering an example Roll
Paper quality depends on several issues like theraw materials, the mixture of them, the shortcirculation and after that the head box and theformer of the paper machine. All these are crucialfor the final paper quality and the mistakes takenin these phases are impossible to correct later inthe process.
After these the quality is made or totally destroyedy e ro s n e paper mac ne, coa ng mac ne
or calanders. It requires a lot of know how andexperience to know when each roll in its ownposition is good enough to perform its own task in
e process. ome ro s are us o ea e paperinto the next phases of the process but most of
them are doing something for the profile or thesurface of the paper - the quality.
A roll maintained and service to a right quality at aright way and equipment at the right time willensure a the quality of the paper.
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 14
I d t i l i t ff i l f
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Industrial maintenance offering an example ofSpecial Services to Support Maintenance Agreement
PreventiveTheoretical production time
maintenance
Service
Spare check
Planned production timeNon-
production
time
Drives
Remote
controlGross operating time
Availability
losses
Equipment & process
failures
Planned shuts and
set-up& adjustments
Drives
LoopPerformanceNet operating time
Speed
losses Reduced speed
Idling and minor
stoppages
p m za on
WIS
Site survey
QCS
Valuable
operating t ime
Quality
losses
Defects in process
Start-up lossesProcess
Analysis
Trim audi tsProcess
Optimizer
stability
AuditOEE Online
measurement
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 15
nergy mgm
& optimization
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Summary
Down-turn has clearly affected to development of maintenancemar e .
Indication that outsourcing trend will continue
specialists support
We need constantly new ideas and innovations on how to keep.
Best and most remarkable renewals and new ideas forimprovement come from an industry or business outside of your
.
ABB Full Service is focusing on several, but carefully selected,
industry areas, Pulp & Paper, Oil & Gas, Metals and Mineralsav ng e compe ence requ re or e n us ry spec c ssues
as well as the variety of overall maintenance similar to allindustries.
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 17
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Summary
An Industrial Maintenance Provider has to have the capability,know-how, recourses, partners and network to manage andexecute all maintenance activities in the entire lant.
ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 18
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ABB GroupSeptember 1, 2011 | Ver. 1.1 Slide 19