It’s all about performance
ABB Services
You must get more out of the money you spend.
We know the following industry trends are driving you to get as much performance out of your assets as possible:
Less capital spending
The big automation and information capital improvement era is over. There is significant pressure to lighten the balance sheet, increase cash flow and improve earnings. You must focus on making improved use of existing assets.
Fast technology change drives outsourcing
The fast pace of change, and the continuing pressure to reduce cost by reducing personnel makes technology difficult to manage. Companies today must look outside for the expertise they used to have inside.
Emerging technologies demand new knowledge needs
Emerging automation technologies increase the need for new knowledge. Ensuring that your personnel can best utilize cutting-edge technology is becoming more and more challenging.
Increased focus on core business
In today’s highly competitive environment, it is critical to focus on core business activities and seek alternate means of handling non-core, yet essential, aspects of operations.
These are challenging issues. We can help you address them.
While some process and manufacturing industries score high return on assets, such as pharmaceuticals and mining, crude oil production; others score quite low, such as forest & paper products and metals. Industrial services can significantly boost return on assets.
Source:The 2004 Fortune 500, Top Industries: Most Profitable Industries: Return on Assets, April 5, 2004, http://www.fortune.com/fortune/subs/fortune500/topperformers/industrysnapshot/0,19724,prof_pct_assets, 00.html, Retrieved on July 23, 2004
Rank Industry 2003 %
1 Household and Personal Products 13.5
2 Pharmaceuticals 10.3
3 Medical Products & Equipment 9.1
4 Homebuilders 8.8
5 Food Services 8.7
6 Publishing, Printing 8.0
7 Apparel 7.9
8 Mining, Crude-Oil Production 6.4
9 Specialty Retailers 6.3
10 Consumer Food Products 6.1
11 Health Care 6.0
12 General Merchandisers 5.6
13 Petroleum Refining 5.2
14 Electronics, Electrical Equipment 5.2
15 Wholesalers: Health Care 5.1
16 Computer & Data Services 5.1
17 Engineering, Construction 4.5
18 Beverages 4.1
19 Chemicals 4.1
20 Wholesalers: Food and Grocery 4.0
21 Automotive Retailing, Services 3.9
22 Aerospace and Defense 3.3
23 Wholesalers: Diversified 3.1
24 Industrial & Farm Equipment 3.0
25 Food Production 2.9
26 Food & Drug Stores 2.8
27 Railroads 2.8
28 Network & Other Communications Equip. 2.8
29 Utilities: Gas & Electric 2.7
30 Pipelines 2.5
31 Hotels, Casinos, Resorts 2.4
32 Entertainment 2.4
33 Diversified Financials 2.3
34 Wholesalers: Electronics & Office Equip. 2.1
35 Insurance: P & C (stock) 2.1
36 Telecommunications 1.9
37 Computers, Office Equipment 1.5
38 Commercial Banks 1.3
39 Motor Vehicles & Parts 1.0
40 Forest & Paper Products 0.9
41 Insurance: Life, Health (stock) 0.7
42 Securities 0.7
43 Airlines 0.4
44 Metals 0.2
45 Packaging, Containers 0.0
46 Semiconductors & Electronic Components -1.5
47 Energy -1.7
ABB Services
ABB is one of the world’s largest automation companies with a wide range of automation offerings and an extensive, global installed base of control, motion and robotic products and systems.
Providing world-class support to ensure maximum performance of your ABB automation equipment investment is important to us.
Our complete portfolio of services and service prod-ucts – from spare parts to consulting, optimization, and outsourcing services – can help to maximize your ABB investment by:
• Improving equipment productivity
• Minimizing costs throughout the equipment life • Extending the useful equipment life
With more than 10,000 service professionals worldwide, we get the job done, when it’s needed, where it’s needed.
Service Portfolio
Page
Maintenance & Field Services ... 4
Installation & Commissioning Predictive, Preventive and Corrective Service Contract Agreements
Optimization Services ... 5
Overall Equipment Effectiveness (OEE) Review & Measurement tools
Spare Parts & Repair Services ... 6
Parts
Version Management Legacy Support Test & Inspection Repair & Refurbishment Web-Based Parts & Repair Parts Assurance Program Parts Inventory Management
Support & Remote Services ... 8
Web-Based Support Telephone Support
Remote Condition Monitoring
Migration & Retrofit Services ... 10
Migration Planning Migration Implementation Standard Migration Packages
Training Services ... 12 Product Programs Process Programs Custom Courseware Coaching Training Assessment
Third-Party Technology Programs Competence Development Practice eLearning
Performance Services ... 14
Consulting
Equipment Performance Management ABB Full Service®
Automation Performance Management
ABB Products and Industries Served
Analytical Control Force Low Voltage Propulsion
Products Systems Drives Measurement Instrumentation Products Motors Systems Robotics Turbochargers
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Products IndustriesMaintenance
& Field Services
Maintenance & Field Services
Our service team is global, with more than 10,000 profes-sionals providing fast and efficient response to your service needs. Our service professionals are trained and certified to help you avoid downtime and get you back on-line as quickly as possible. We know that the key to providing world-class service is not only to respond quickly, but also to provide better solutions than can be found elsewhere.
Installation & Commissioning
ABB service engineers provide expert on-site Installa-tion & Commissioning of ABB products and systems. Our startup and commissioning services span from installation support to full project management.
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• Smoother installations • Faster start up at lower cost • Improved efficiency
Predictive, Preventive and Corrective
Effective Predictive, Preventive and Corrective mainte-nance practices maximize the performance of your automation and production equipment. ABB service personnel are trained in the latest diagnostic, repair and maintenance practices to ensure high value for your maintenance investment. Maintenance solutions such as condition monitoring help to predict equipment failure and prevent costly downtime.
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• Reduced mean time to repair • Increased plant performance
• Higher overall equipment effectiveness
Service Contract Agreements
We recognize that your specific service requirements are based on the criticality of your assets to production, and the level of in-house expertise you expect to maintain. An ABB Service Contract Agreement is custom tailored to compliment your in-house expertise and provide the additional capabilities needed to maintain site asset performance at the required level. Agreements ranging from call-up support services to compliment a self-maintainer maintenance strategy, to multi-engineer resident service contracts, to complete maintenance outsourcing are available to meet your unique mainte-nance service needs.
Our experienced service professionals can help you to identify and implement effective contract maintenance programs for your operation, that can reduce cost and improve uptime by maintaining equipment at peak performance levels.
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• Expanded maintenance capabilities • Improved equipment utilization • Effective maintenance planning
“ABB has given us access to maintenance data and knowl-edge we never had before, and uncovered the competitive advantage in highly effective maintenance systems.” –
Kunda Nordic Cement optimizes production with new maintenance approach
Faced with increasing environmental regulation and globalization issues, Kunda Nordic Cement (KNC) in Estonia needed to change its maintenance practices and tools. The plant,
built more than 40 years ago, never achieved full capacity since only two of four kilns were ever put into operation. In 1998, KNC called on ABB to modernize its maintenance. ABB worked closely with KNC to identify and implement
immediate maintenance actions to improve and guarantee optimum production. This included a cultural change from a “break and fix” attitude to a preventive approach.
Today, the production at KNC is higher with just two kilns than its original goals using all four.
Optimization
Services
Optimization Services
Plant automation provides access to abundant and valuable process, production and equipment feedback data. The ability to analyze and utilize data effectively is key to decision-making and response. ABB Process and Asset Optimization Services use a proven, continuous improvement methodology, special tools, and knowledge of the systems and processes in your operation to identify and release valuable improvement opportunities currently hidden in your production assets.
The OEE Model
Overall Equipment Effectiveness (OEE)
Optimization begins with discovery and analysis of potential process and asset improvement areas. Our Overall Equipment Effectiveness model applies a time-proven analysis methodology, which uncovers and measures potential benefits. This model centers on the measurement of existing relationships between equipment availability, efficiency, and rate of quality production. Analysis of these relationships
can uncover substantial performance improvement opportunities in several targeted areas.
ABB engineers will present findings of the analysis and specific recommendations. They can provide a customized implementation plan. Implementation services can then be provided by ABB engineers or can be integrated into your site maintenance schedule and carried out by your in-plant personnel.
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• Optimized process for maximum quality and productivity
• ABB-specific tools for accurate analysis • Lower maintenance cost
Review and Measurement Tools
Stand-alone, targeted services are also available to review specific areas of your systems and process.
– Power Quality & Grounding Review – Network Communications Review – Distributed Control Systems Services:
Lifecycle Evaluation, Hardware Review, Software Review, Communications Review – Maintenance Fingerprint
The OEE Equation
OEE = Availability x Efficiency x Quality
Targeted Performance Improvement
Areas
Potential OEE improvement can be effectively measured and compared with actual data after optimization services are implemented.
A – Availability E – Efficiency Q – Quality Defects in Process & Rework Equipment Failure Setup & Adjustment
Idling & Minor Stoppages
Reduced Speed
Startup Losses
Spare Parts
& Repair Services
Spare Parts & Repair Services
ABB’s global logistics network is strategically positioned to provide fast parts and repair service throughout the world, 24-hours a day. Our global organization uses standardized processes, tools and metrics to ensure that components are delivered efficiently to your site.
Parts
Spare parts availability is critical to on-going operations. We maintain a complete stock of certified ABB parts, guaranteeing availability. For emergency replacement parts, our logistics personnel and partners are available 24-hours a day to provide immediate response to your emergency parts request.
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• High-quality, certified parts
• Improved uptime due to guaranteed delivery • Global logistics network ensures fast delivery
Version Management
Version Management is important to the integrity of your system, and can directly impact performance by guaran-teeing that modules are at current revisions and spare inventory is functionally compatible with your installed equipment. ABB, as part of a service agreement, will inspect and ensure that the latest revisions are completed and will update your module inventory to ensure optimal system functionality.
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• Minimal downtime • Reduced potential rework • Maximum asset performance
Legacy Support
Our Legacy Support provides replacement parts and repairs for previous generations of ABB systems. Access to global-parts inventories facilitates availability of new and refurbished parts for your legacy system. Repair and parts services for ABB legacy products are available as long as they are technically and commercially feasible.
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• Extended system lifecycle • OEM-ensured parts quality • Reduced downtime
Test & Inspection
Our ISO 9002-certified testing centers utilize state-of-the-art automated test equipment (ATE) that is used in component-level, multilevel, in-circuit & full-functional testing, and environmental stress testing. Our certified technicians are qualified to test and inspect your parts from ABB and other manufacturers.
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• Minimized downtime
• Improved return on parts investment
• Streamlined sourcing for parts testing needs
Repair & Refurbishment
Repair or refurbishment of malfunctioning or failed compo-nents is an economical alternative to new part replacement. Our ISO 9002-certified repair network provides repairs, reconditioning and version management services that meet or exceed original equipment specifications. Our world-class cycle time for repairs is typically less than two weeks. Emergency repairs can be completed in as little as one day. A full one-year warranty is included with every repair and refurbishment service for ABB and qualified non-ABB products and systems.
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• Maximum return on parts investment • Extended product life
• Increased reliability
Downtime dropped significantly after several installed drives in one facility were refurbished during 2001 and 2002. The updated drives attributed to zero downtime hours in 2002.
ABB turns weeks into days for paper mill
When a calender stack disaster destroyed an ABB scanner, the AssiDoman Kraftliner mill production director feared the worst. Instead he got ABB’s best effort.
Immediately after losing the scanner, an urgent request was placed for a new one. Production Director Tore Person expected
weeks before delivery to his Pitea, Sweden-based mill. But ABB’s global resources joined together and delivered the equipment from Ireland via a Russian military cargo plane within three days.
“I felt so relieved when the Russian cargo plane landed,” said Person. “I knew then ABB was going to save us from weeks of downtime.” “ABB exceeded our expectations.”
Web-Based Parts & Repair
24-hour, web-based parts and repair ordering capabilities include access to thousands of ABB products, parts, and repair services. Use secure Internet tools, to view current pricing, availability, order acknowledgment & tracking, order history information, and more.
To register for free access contact your local ABB service representative.
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• 24-hour access to ABB products, parts and repair ordering and information
• Improved ordering efficiency through order integration into your Enterprise Resource Planning system • On-line order verification and visibility
Parts Assurance Program
ABB Parts Assurance Program is a component of an ABB Preventive Maintenance Program or an Instrumentation Maintenance Program. It allows effective planning and cost management of spare parts budgets. A fixed, monthly charge covers all replacements and repairs for parts specified in the program.
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• Reduced risk • Improved planning • Capital flexibility
Parts Inventory Management
Our Parts Inventory Management program, Inventory Access, provides a customized spare parts inventory at or near your location – owned and maintained by ABB. We maintain full responsibility for obsolescence, depre-ciation, administration, and inventory ownership costs until the parts are placed into service. A fixed monthly fee provides the security of on-site parts availability, while reducing your initial capital expenditures for a spare parts inventory.
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• Knowledgeable parts management • No up-front capital expenditure for parts • Managed obsolescence
Contact your local Service Account Manager to request free access to web-based parts ordering capabilities.
Support
& Remote Services
Telephone Support
Our telephone support system provides reliable 24-hour access to ABB support resources who understand the urgency and importance of your support request. Each call is efficiently routed to an appropriate expert who will personally follow your request to resolution. An ABB SupportLine or SupportLine Plus telephone support contract provides the added benefit of guaranteed response time and priority call status.
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• Fast support case resolution • Emergency call support 24/7
• Subscription plans to suit your needs and budget
Support
& Remote Services
Advanced remote technology delivers higher service value and performance. Remote Services extend assistance for a wide range of support needs. From telephone and self-service web support to direct and secure system interaction, remote services provide real-time direct access to global technical specialists and service experts 24-hours a day.
Web-Based Support
Our Web-Based Support service, SolutionsBank, provides on-line access to more than 60,000 technical documents and a wide-range of support solutions. Web-Based Support provides instant access to product documentation, software downloads and reports that you need to support your operation. Activate Auto Notification and receive email notifications of updates for products included in your installed equipment profile. View technical information and video instructions, track service call progress, download software and updates, even solve your own support case on-line.
A SolutionsBank subscription gives you access to 24-hour self-service support. A complimentary subset of ABB technical information and downloads is also avail-able. For additional information visit SolutionsBank on-line at: http://SolutionsBank.abb.com
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• Save time and money through self search • 24-hour access to technical solutions • Faster access to support resources
– Knowledge Navigator, a SolutionsBank software
add-on, works seamlessly with ABB Industrial IT 800 Extended Automation control systems to provide web-based remote access to trouble-shooting and support information. Workstation icons link directly to appropriate support material in SolutionsBank using standard 800xA aspects.
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• Higher value from Industrial IT control systems • Faster resolution using context-sensitive information • Lower support costs through self-help tools
How ABB Provides
Analysis & Feedback Layer Communication Layer Connection Layer Marine Industrial IT Enabled Products & Systems Control Systems Propulsion predictive maintenance Web-based maintenance management software Asset optimization • Field Engineer • Global Resources Internet – Modem –
Remote Services utilize existing and cutting-edge technologies to provide valuable diagnostic and monitoring services.
ABB empowers papermaker operators with on-line maintenance information
The benefits of Knowledge Navigator, a subset of SolutionsBank, were immediately evident to a U.S. paper company. By providing direct, context-sensitive access to SolutionsBank from operator stations, operators were able to be proactive in settling machine issues on their own, rather than waiting for maintenance personnel to respond. The papermaker used Knowledge Navigator to
troubleshoot system-generated alarms. It can easily search SolutionsBank, locating possible solutions. Operators can take action based on the recommendations or escalate the issue to their on-site maintenance staff.
Remote Condition Monitoring
Remote Condition Monitoring services improve plant-wide reliability by effectively predicting equipment irregularities. Data gathering methods range from manual periodic collection, to continuous 24-hour monitoring. Your in-plant personnel or our global experts can evaluate data, using our proven diagnostic software. Offerings are available to address both high-and low-cost assets.
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• Remote access to expert analysis • 24-hour, continuous asset monitoring • Proactive intelligent-action feedback
Support & Remote Services - see also:
Web-Based Parts & Repair --- 7 eLearning --- 13
Marine industry benefits from remote analysis
ABB’s remote vibration analysis contract with a U.S. government organization, operating a fleet of vessels worldwide, has been in place for over 25 years. The customer’s average benefit-to-cost ratio of over 20:1 is a product of 5,000+ annual machine tests. Two-thirds of the cost savings are linked to improved selection and prioritization of machines scheduled for repair or overhaul. The remaining one-third of the documented savings centers on early fault detection, resulting in prevention of progressive machine damage. ABB’s skilled vibration analysis and proven fault diagnostic software has improved labor efficiency and machine reliability while reducing overall maintenance costs.
Remote Services
Instrumentation & Low-Voltage
Products
Drives
& Motors Robotics
On-line parts Remote drive monitoring Remote robot services
• Technical Support Resources • Global Centers of Excellence – Direct Line – Etc.
Migration
& Retrofit Services
Migration & Retrofit Services
The ABB lifecycle management model provides the framework used to develop and provide evolutionary services that maximize availability and performance throughout the life of ABB equipment. This model enables ABB to provide optimum support to end-users and a smooth transition to new software and equipment when a product reaches the end of its lifecycle. Many ABB products provide useful service for twenty years or more. Throughout the product lifecycle, we work to provide solutions that expand the functionality and extend the lifecycle of your equipment, while maintaining your core investment.
Migration Planning
ABB Migration Planning services can help you to develop your long-term evolution roadmap. Planning today can help you to budget funding for upgrades and avoid unplanned capital expenditures in the future. Our unique service approach to migration planning follows your strategy – not ours. We provide the technical information you need to determine which evolution strategy is compatible with your current strategy and would provide the most benefit. Our structured criticality analysis and product supportability report will provide you clear “Replace, Migrate, or Maintain” options. We can help you to plan a strategy which fits within existing budget constraints, allows maximum benefit from your investment, and ensures your existing capital investments maintain top performance.
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• Identify upgrade opportunities with greatest ROI • Access to ABB evolution experts
• Cost-effective solutions
Migration Implementation
ABB Migration Implementation services provide a comprehensive upgrade implementation option for ABB equipment. Services are efficiently managed as projects, and utilize established engineering practices and tools to ensure that all necessary details are identified and addressed during the project. Our dedicated migration team ensure equipment compatibility and smooth transi-tion to next-generatransi-tion technology when needed. Deciding on appropriate migration or retrofit services for your installation is best accomplished through Migration Planning Services. A yearly planning session with your ABB service team is recommended to identify long and short-term optimization opportunities and benefits.
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• Simplify expansion and replacements • Low risk migration
• ROI-based upgrades
Standard Migration Packages
Standard Migration Packages are available for many ABB products and systems. Software, hardware and firmware upgrades for standard products are available.
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• Simplified upgrade process • Reduced downtime
• Minimized maintenance costs
Clear Evolutionary Path Forward for a Wide Range of ABB Product Lines • ABB • A-B/S • AccuRay® • Alfa Laval • ASEA • Bailey • BBC
• Fischer & Porter • Freelance • Hartmann & Braun • INFI®90 • ITE/Gould/Kelman • Kout • Maestro • Master • MOD 300 • Moloney • Network 90® • Schneider
• Schoppe & Faeser • Stromberg • SYMPHONYTM • Taylor
• TBI
Preparation and collaboration provide seamless migration to Industrial IT technology
Citizens Thermal Energy (CTE), located in the U.S.A., chose to upgrade their 15-year old NET 90 DCS system with ABB’s Industrial IT control system technology. The upgrade combined two Symphony control loops and a third-party control loop into a single system using ABB’s Operate IT Process Portal.
“ABB was open to our concerns,” said Mark Vogler, CTE Manager of Engineering. “They listened and gained a good understanding of what we needed.”
The new streamlined set-up is highly efficient. The user can easily move data across different areas of the business and constantly monitor operations from various computer screens. This efficiency is extremely important during emergencies, when seconds count.
Vogler said that ABB’s close collaboration with CTE technicians allowed implementation of this solution without a unit outage.
“We hope to continue our relationship with ABB so we can further improve our processes and keep pace with technology.”
Migration Management
As we map our customers’ technology needs, explore alternative solutions, and leverage emerging technolo-gies, we ensure that we retain the competence to deliver engineering solutions for tomorrow.
Based on existing requirements and lifecycle status, ABB migration teams recommend and develop timely, cost-effective solutions that efficiently address evolving market opportunities and demands.
Lifecycle Management
ABB’s Product Lifecycle Management Model is com-prised of four phases: Active, Classic, Limited, and Ob-solete. It is reviewed regularly to ensure support options are available and evolutionary pro-grams are in place to maintain your core invest-ment throughout the complete product lifecycle. Evolution products simplify the upgrade process, by extending product life-span and optimizing system and component performance; while maximizing return on investment and delaying obsolescence.
– StepUp Programs simplify the upgrade process,
provide enhanced performance capabilities, and maxi-mize the value of installed systems and components. ABB StepUp programs also minimize maintenance costs and reduce downtime. As an added advantage, all StepUp services are designed to allow existing data to be used with upgraded systems. Complete upgrade support is available and provided by ABB StepUp teams.
– Software Management Programs range from
soft-ware consulting to our complete softsoft-ware management program, SoftCare. SoftCare provides software manage-ment for ABB automation products, combining a soft-ware subscription services with basic softsoft-ware support. ABB service support engineers are available to assist your personnel or completely manage your software program, including software archiving and validation.
Evolution Through Enhancement
ABB’s Migration Planning Services simplify the process of upgrading your existing technology, while maintaining your current system investment.
Control System “Evolution Through Enhancement” strategies are available for Harmony/INFI 90, MOD 300, DCI, Melody, Master, Satt, Contronic, and Freelance Control Systems.
Training
Services
Training
A skilled and efficient workforce is a plant’s most valuable asset. We can help to increase workforce skill levels and knowledge, providing more productive response to system and process challenges. Our training programs for engineers, programmers, maintenance, and operations personnel provide comprehensive and up-to-date technical expertise for existing and new products, processes, and technology advances. Training is available on-site at ABB training facilities, locally at your plant site, or on-line.
Product Programs
Our operator and maintenance training ensures your personnel anticipate and respond correctly to system and process challenges, avoiding lost production.
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• Improved production • Increased uptime • Higher asset utilization
Process Programs
Effectively tuned control loops provide efficiency and optimal performance – saving you thousands of dollars per year. Our process training programs illustrate state-of-the-art control design, setup and demonstrate tuning techniques that deliver enhanced equipment performance.
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• Reduced raw material costs • Reduced customer quality rejects • Shorter problem resolution times
Custom Courseware
We offer customized curricula to address the unique training requirements of your facility. We provide assessment, planning, development, and delivery of specialized programs to improve performance and increase productivity.
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• Increased employee productivity • More focused use of training investment • Access to qualified training personnel
Research has shown that in most cases, only about 40% of equipment features are utilized. ABB University training enables our customers to take maximum advantage of every bit of the technology we bring to market.
System performance ROI
ROI with trained staff ROI with poorly trained staff Well-trained engineers
deliver faster start-ups
Start-up complete
Human performance drops as new engineers and maintenance staff are given less training Time
Continuous training delivers improved results by using the latest methodologies
Maintaining personnel skills through targeted training programs ensures short- and long-term performance benefits.
ABB University – delivering training worldwide
Coaching
Coaching is an effective post-training and refresher strategy for maintaining skill level and competencies. ABB Coaching services are provided on-the-job at your plant site or over the Internet. A skilled ABB training professional will work with your personnel through daily routines to solidify and reinforce required skills.
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• Increased efficiency • Accelerated learning
• Access to qualified training personnel
Training Assessment
Our Training Assessment process identifies which training program would best satisfy your training needs. We offer a comprehensive, plant-wide skills evaluation and training delivery programs to fill knowledge gaps and improve skills of plant personnel.
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• More effective use of training investment • Comprehensive needs identification • Improved personnel development planning
Third-Party Technology Programs
Achieving maximum return on your investment often depends on equipment communication and interactivity with “the outside world.” Our third-party technology training programs build competence in networking, operating systems, and related technologies to maximize your equipment investment payback.
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• Maximum return on equipment investment • Technologically up-to-date personnel • Improved technology implementation
Competence Development Practice
We offer our Competence Development Practice (CDP) for customers looking for a comprehensive approach to people development. CDP facilitates the identification of the required skills in your workforce, identifies the existing gaps, recommends the appropriate training programs to remove the gaps, monitors skill retention, and recommends follow-up training to sustain required workforce skills.
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• Sustained retention levels • Higher asset utilization
• Improved personnel productivity
eLearning
ABB eLearning services provide a high-quality, cost-effective alternative to traditional classroom learning. eLearning offerings include:
– Virtual Classroom training delivers real-time
interaction with a live instructor and application sharing from your computer. Course subject matter is reinforced through related off-line assignments.
– Web-based training (WBT) provides on-line access
and completion of courseware modules directly from our website: www.ABB.com/ABBUniversity
– Computer-based training (CBT) utilizes CD
ROM-based licensed software. It enables contained, self-paced learning from any computer workstation.
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• Lower training costs • Flexible scheduling • Self-paced learning
Weyerhaeuser improves human performance
The Weyerhaeuser Dryden pulp and paper mill in Canada acquired new air emissions technology. The company turned to ABB for required employee training.
ABB used its Competence Development Practice (CDP) to develop a “what” and “how” implementation plan to best prepare Dryden’s workers for the changes ahead. According to Stephanie Armstrong, Training Coordinator for the Weyerhaeuser Company, “ABB helped us align the training objectives with our desired outcomes, and then delivered the courses aimed at our employees’ needs,” she said. “ABB was the only supplier to offer a training package in line with what we were looking for.”
“We’re able to see the results of CDP in real-world situations, like when equipment goes down,” she added. “How employees respond to these challenges tells us that our training dollars have been well spent.”
Performance
Services
Performance Services
Getting the most from your assets requires an in-depth knowledge of both process strategy and the equipment used to enact that strategy. Access to the high-level expertise required to make value-generating business decisions is a benefit of working with ABB Performance Services. ABB Performance Services provide a wide range of value-enhancing services dedicated to accelerating your return on investment by reducing cost and increasing asset effectiveness. ABB’s technology and application experts work side-by-side with your plant personnel to develop solutions that are directly linked to business objectives and the critical capabilities required to support them.
Consulting
ABB Consulting Services identify valuable opportunities for improvement in production processes and operations infrastructure. Our consultants have in-depth knowledge of best practices in a wide range of business and engi-neering operations. Key consulting services include:
– Plant Performance Benchmarking leverages proven
methodologies to assess performance, effectiveness, reliability and capability of production assets and processes relative to the best-in-class for each customer industry.
– Sustainable Maintenance Excellence programs
are developed to improve maintenance effectiveness by optimizing management practices, resulting in lower unit production costs and operations expenditures.
– Safety, Health and Environmental Excellence is
focused to improve the safety culture within your facility, this ensures regulatory compliance and safeguards your licenses to operate.
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• Quantified analysis of asset performance and effectiveness
• Ensured environmental and regulatory compliance
Equipment Performance Management
Equipment Performance Management (EPM) optimizes the total lifecycle of specific asset classes, such as motors, drives, automation systems, breakers, and transformers. With EPM, ABB assumes responsibility and accountabil-ity for the management of your equipment, with prioraccountabil-ity on energy and automation chains. This includes ABB products and systems, as well as similar products from other manufacturers, and tightly linked equipment. Within a long-term partnership, ABB guarantees the performance of covered assets under a fixed cost and performance-based contract.
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• Increased production reliability • Reduced total cost of maintenance • Extended asset life
Example based on 232 plants in the same industrial field Best in Class Plant Measurement Worst in Class Capacity Quality Maintenance Energy & W aste
Health, Safety &
Envir
onment
Yield
Plant Performance Benchmarking
Consult Collaborate Create Value
ABB Full Service
®ABB is a global leader in maintenance outsourcing, with more than 150 ABB Full Service partnership agreements around the world. Full Service programs are developed to improve maintenance effectiveness by optimizing management practices, resulting in lower unit production costs and operations expenditures.
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• Increased asset effectiveness • Reduced operating costs
• Sustained productivity improvements
Automation Performance Management
Automation Performance Management (APM) is a unique co-sourcing agreement that replaces capital-intensive automation strategies with performance and usage-based service agreements for automation. Unlike traditional outsourcing agreements that provide services for client-owned assets, an Automation Performance Management agreement shifts the burden of owning and maintaining the infrastructure to ABB, allowing our customers to increase their focus on core competencies. Under the ABB performance partnership model, our compensation is tied directly to production outcomes, providing you the confidence of assured improvement, combined with the comfort of global support.
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• Key performance indicators control compensation • Performance risk transferred to ABB
• Eliminates risk of obsolescence
Copper manufacturer gets focused for success, thanks to ABB
The decision to focus on its core business, copper production, turned out to be a wise one for Outokumpu Harjavalta Metals Ltd. Outsourcing support tasks was a critical part of that successful strategy. So was the decision to select ABB as its maintenance partner. “ABB’s assumption of the
maintenance function was well-designed and exemplary,” says Pentti Ahola, director of Outokumpu Harjavalta Metals Oy. Since ABB took over maintenance functions, costs have dropped and production has increased.
“Last year was our best ever, both operationally and in terms of production,” says Ahola.
ABB helps Southeast Asia’s largest petrochemical complex become one of the best
Forty ABB consultants from three continents are converging on Thailand to carry out a fast-track technical audit that will enable the biggest petrochemical complex in Southeast Asia to measure and improve
its performance.
The audit is a key element of a restructuring plan that will determine what the company must do – and what it will cost – to improve performance and ensure regulatory compliance and operational reliability.
The audit consists of a site economic and criticality study, a technology assessment, and a review of maintenance practices and health and safety processes.
The restructuring coordinator said ABB was selected because of its “competence in the petroleum and petrochemical industries and prior experience in Thailand. ABB demonstrated a strong commitment to the project and offered the best value proposal.”
A Full Service contract can reduce maintenance cost, typically 15% to 20%, while improving Overall Equipment Effectiveness (OEE).
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Full Service Contract Results
Profit Increase
Productivity Improvement
Cost Reduction
3BUS 022 950 R003 2M Litho in USA 804
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Specifications subject to change without notice. Pictures, schematics and other graphics contained herein are published for illustration purposes only and do not represent product configurations or functionality. User documentation accompanying the product is the exclusive source for functionality descriptions.
