1. ABB Reliability Fingerprint
Consulting services for all industries
ABB Reliability Fingerprint
Identifies opportunities for productivity, reliability and cost improvement

2. If only it were this simple…
I found the problem. The batteries are upside down.

3. Introduction
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

4. Benefits 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

5. Three-part assessment
Overall Equipment Effectiveness (OEE)
Composite measure of equipment availability, production rate and quality
Maintenance Performance
Evaluates maintenance practices: Utilization, Methodology, Performance
Reliability Culture
Evaluates roles and responsibilities, reliability training, failure analysis
Reliability-centered maintenance (RCM)
Root cause analysis (RCA)

6. Description Periodic assessment
Price based on number of Full-time Maintenance Employees (FTEs)
$15,000: <50 FTEs
$20,000: maintenance FTEs
$25,000: 100+ maintenance FTEs
Performed by Reliability Service team
2-Week program (week 1: data gathering, week 2: analysis and reporting off- site)
1-2 consultants per week
Deliverable
Qualitative assessment of plant reliability and improvement plan
Quantitative assessment of financial business opportunities

7. 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 = $31, PM2 = $67,419
Total for both machines Year 2 = $98,820
Each extra or marginal ton of PM1 availability = $300 ($756/hour)

8. Evaluates process and assets
1. OEE assessment
Evaluates process and assets
Equipment
Availability (A)
Maintenance Mgr.
Production Rate (P)
Production Mgr.
Quality Factor (Q)
Quality Mgr.
Financial Mgr.
Product
People
Material
HR Manager
Supply Manager
Profit
Plant VP/Manager
Applies proven analysis methodology
Measures relationships
Equipment availability
Production efficiency
Rate of quality
Uncovers potential benefits

9. 2. Maintenance Performance Assessment
Includes maintenance cost
Financial Mgr.
Maintenance Mgr.
Production Mgr.
Quality Mgr.
Product
People
Material
HR Manager
Supply Manager
Profit
Plant VP/Manager
Utilization
Time spent waiting
Craft coordination
Availability of drawings
Craft flexibility
Parts availability
Level of rework
Methodology
Business processes
Planning
Special tools
Scheduling
Standard jobs library
Rebuild procedures
Performance
Skills
Training
Job interruptions
Supervision
Morale
Labor issues
Precision maintenance

10. 3. Reliability Culture Assessment:
Roles and responsibilities, reliability training, failure analysis
Financial Mgr.
Maintenance Mgr.
Production Mgr.
Quality Mgr.
Product
People
Material
HR Manager
Supply Manager
Profit
Plant VP/Manager
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

11. Information Gathering
Primary Activities
Information Gathering
(On- and off-site)
Analysis
(off-site)
Delivery
(on-site)
1 Week on-site
Pre-arrival data collection packet
Collect Data on-site
Validate Data
Confirm information understanding with Customer
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
Present Reports

12. Assessment Evaluation
The assessment findings are reviewed by a collaborative Reliability/ABB Field Services Team
The team maps service portfolio opportunities to identified performance gaps

13. Set-up and adjustments Idling and minor stoppages
OEE Overview
Total Available Production Time
Planned production time
Non-
production
time
Planning
Factor (Pf)
Gross operating time
Availability
Losses
Availability
Factor (A)
Equipment failure
Set-up and adjustments
Net operating time
Speed
Losses
Performance
Factor (P)
Idling and minor stoppages
Reduced speed
Valuable operating time
Quality
Losses
Quality
Factor (Q)
Defects in process
Start-up losses
OEE %
Availability
factor (A)
Performance
factor (P)
Quality
factor (Q)
Valuable operating time
Planned production time = X X =

14. Sample Deliverable OEE Waterfall – PM 1: OEE = 75%
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Total Time (hours) (8760 hrs)
Steam (2 hrs)
Electrical (98.1 hrs)
Other (5.1 hrs)
Planned Production Time ( 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 ( hrs)
Quality Losses (730 hrs)
Making Good Product at MPR ( hrs)

15. Maintenance Performance Example:2 4 6 8 10 12 14 20 5 15 25 30 35 40 45
Maintenance cost as % of facility replacement cost
Facility number
Your facility
World class
1.5% – 2.0%
Maintenance Cost is tied to:
Effectiveness of maintenance
Skill level and quality of knowledge of personnel
Asset type
% of unplanned maintenance
% of predictive maintenance
Example PM#1 - Vibration detects bearing wear
Proactive Maintenance - Bearing is changed (cost $5,000)
Reactive Maintenance - Bearing is not changed, Machine fails (cost $100,000)

16. Areas evaluated with fingerprint
Reliability Culture Areas
High
dB Avg
Site Score
Low
Continuing Education
Performance Assurance
Roles and Responsibilities
Responsive Maintenance
Preventive & Predictive Maint.
Management Leadership
Organizational Structure
Supplier & Services - Stores
Physical Assets Program