daanotter ppa dag 2010 - fhi · © abb group march 25, 2010| slide 1 asset management of analyzers...
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© ABB Group March 25, 2010 | Slide 1
Asset Management of Analyzers
Daan Otter PPA Dag 2010
© ABB Group March 25, 2010 | Slide 2
ABB Products and Systems from 5 divisions
Robots, peripheral devices and modular manufacturing solutions for industry
ProcessAutomation
Sales: $5.0 billion
Control systems and application-specific automation solutions for process industries
Substations, FACTS, HVDC, HVDC Light, power plant & network automation
Power Systems
Sales: $4.0 billion
Robotics
Sales: $1.7 billion
Transformers, high- and medium-voltage switchgear, breakers,automation relays
Power Products
Sales: $6.4 billion
AutomationProducts
Sales: $5.9 billion
Low-voltage products, drives, motors, power electronics.
n Market-leading positions in most key product areasn Integrated solutions for grid reliability, productivity and energy efficiencyn Robust global value chain to serve established and emerging marketsn Extensive global network of value-added channel partnersn Market leader in industrial servicesn ABB Installed Base value USD168 Billion
© ABB Group March 25, 2010 | Slide 3
Value Chain & Installed Base Management
§ Installed Base (IB)§ Consists of ABB produced products and systems
delivered to ABB customers
§ Starts at installation and ends at de-commissioning
§ Installed Base Management§ Is planning and execution of service and support
the ABB Installed Base
§ Generates customer satisfaction and a competitive advantage
§ Is a part of ABB service business.
§ ServIS is an IS system, a tool, to support Installed Base Management
Sales/
Proposal Eng
Business/Scope
Approval Production Integration LogisticsInstallation
CommissionService
6-18mo 6-24 Mo 2-8 wks 6-24 mo 1-20 Yrs
Quotation
Negotiations
Spec’sNew SystemRequirement
Installation &
Commissioning
EngineeringWarranty
Installed base Mgmt
Improving Customer Productivity
© ABB Group March 25, 2010 | Slide 4
Assets
Analyzers
from Transmitter-Type up to complex systems
© ABB Group March 25, 2010 | Slide 5
Cost Emergence
Where are the problems?
Electronics
Sensor Physics
Sample Conditioning
5%
25%
70%
© ABB Group March 25, 2010 | Slide 6
Life cycle-Costs of Analytical Equipment
§ 1/3 Device Costs
§ 2/3 Operating Costs
Service25%
Calibration24%
Maintenance27%
Inspection20%
Documentation4%
source: atp 2/96
© ABB Group March 25, 2010 | Slide 7
Life cycle phases of production tools
n
PRU
Active
DevelopementAnd sales
Classic
Maintenanceof products
Limited
Service and support
Obsolete
Diminishing support and service possibilities
Four Phases of the life cycle
Life cycleStart-up End of warranty
Performancereduction Repair
Revision
Maintenance
ModernisationsRetro fîtReplacement
OptimisationCustomer value
Perf
orm
ance
í
© ABB Group March 25, 2010 | Slide 10
Classic§ maintenance phase of product
Active§ Sales and development
phase of the product
n Product introduction on market
n Acitve sales
n Periodical Evolution of product (improve)
n Active product support
n Product no longer actively sold,
n Full support available
n No more evolution.
n Price evolution (lowvolumes, prices of parts go up…etc.)
Active(~5..10 years)
Classic(~7..10 years)
Limited(~3..5 years)
Obsolete
Obsolete§ End of life of a product
Limited§ support phase
n Spares maybe available but no guarantee
n No more development for obsolete or unavailableparts
n Refurbished parts may beavailable
n No more development of service activities
n Support available but canget less with shrinkinginstalled base (degradingcompetences
n For the major part the costs and technicalrisks become too highto be reasonable
n Some items can bemaintained and repaired for manyyears after
Different life cycle phases over 10---20 years
Life cycle management
© ABB Group March 25, 2010 | Slide 11
Product ProductLine
End ofProductio
nList Layout: A=Active, C=Classic, L=Limited, O=Obsolete
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
AO2000 Uras14 24511 active A A A A A A A A AAO2000 Uras26 24541 active A A AAO2000 Limas11 IR 24921 active A A A A A A A A AAO2000 Limas11 UV 24911 active A A A A A A A A AAO2000 Limas11 HW 24911 active A A A A A A A A AAO2000 Magnos16 24611 2003 A A A C C C C C C L L OAO2000 Magnos17 24621 active A A A A A A A A AAO2000 Magnos27 24642 active A A AAO2000 Magnos106 24613 active A A A A A A A A AAO2000 Magnos206 24641 active A A AAO2000 Caldos15 24711 active A A A A A A A A AAO2000 Caldos25 24741 active A A AAO2000 Caldos17 24721 active A A A A A A A A AAO2000 Caldos27 24742 active A A AAO2000 MultiFID14 24811 active A A A A A A A A AMagnos106 EGA 24616 active A A A A A A A CMagnos206 EGA active A A A ALimas11 EGA 24915 active A A A A A A A A AUras 3G and 3G Ex 20310 1993 C C C L O O O O OUras 3G-H 20314 1993 L O O ORadas 1G and 1G-Ex 20340 1994 L L L O O O O O ORadas 1G-EM 20342 1990 L O O ORadas 1G-H 20344 1993 L O OUras 10 P 20412 1996 C C C C C L O O O
Status Life Cycle Phase
Life cycle management
© ABB Group March 25, 2010 | Slide 13
Reasons for new products
§ Technology shift
§ 1980’s µprocessors
§ 1990’s data communication
§ 2000 LCD/TFT ßà CRT
§ 2010 MEMS
§ Market requirements
§ Rules and regulations
§ Economics
§ Specifications
§ Obsolescence of components
§ Economic lifespan of components reduced
© ABB Group March 25, 2010 | Slide 14
Treating « old » or « obsolete » series
§ ABB’s objectives are:
§ Protect customer’s investment beyond technology shifts
§ Identify obsolete analyzers
§ Structure the handling of the obsolescence
§ Inform about upcoming obsolescence during life cycle
§ Inform customers about the maintainability of their production tools
§ Define technico-economical limits for maintenance and the investmentneeded for treating the obsolescence
© ABB Group March 25, 2010 | Slide 15
Key elements§ Identify the affected analyzers
§ Audit for identifying the installed base
§ Positioning of each analyzer in the life cycle based on factory and/or supplier info
§ Implement a migration plan
§ Take in to account operational constraints and life cycle of the equipment
§ Take in to account market evolution, opportunities and economicalconstraints
§ Develop a common plan together for the modernisation
© ABB Group March 25, 2010 | Slide 16
Analysis of life cycle and obsolescence
§ ABB analytical’s approach by priority
§ Classification of criticality as a function of frequency of malfunction and impact on production
§ Vital, Important, Secondary
§ Classification of criticality as a function of life cycle phase
§ Active, Classic, Limited, Obsolete
§ Classification of criticality as a function of rules and regulations
© ABB Group March 25, 2010 | Slide 18
§ Invest or Maintain? in limited or obsolete phase
Life Cycle
Real depreciation costs
Maintenance
Reduction performanceRepairRevision
Optimisation
Perf
orm
ance
í
Global costsCosts
Maintenance costs
Maintenance effort
Costs due to stops
InvestmentCosts
Economics of obsolescence
Keeping analyzer performance up, requires an ever increasingbudget and effort
Overall costs increase
© ABB Group March 25, 2010 | Slide 19
50+ years of PGC history !
© ABB Group March 25, 2010 | Slide 20
Extending usefull life
§ 2009§ 1985§ With LCD
from 2006
© ABB Group March 25, 2010 | Slide 21
Product and Technology Development
Karl Luft
Erwin Lehrer
1938 First Usable NDIR-Spectrometer Uras (~1950), still running
Uras 1 –License H&B 1952
Uras26
Calibration Cell1988
Advanced Optima1996
Uras 4 – 1980
© ABB Group March 25, 2010 | Slide 22
Advance OptimaThe Modular Concept
YesterdayYesterday
Caldos
Uras 10E
Uras 4
Fidas
Magnos
Uras 10P
TodayToday
Limas
Uras
MultiFID
Magnos
Caldos
© ABB Group March 25, 2010 | Slide 23
Backwards compatible components
§ Syscon 1 à 1996
§ Syscon 2 à 2005
§ Syscon 3 à 2009
© ABB Group March 25, 2010 | Slide 24
Standard System SolutionsComplete and Economic Analyzer Systems
TodayYesterday
© ABB Group March 25, 2010 | Slide 25
Installed Base Management process
§ Use ServIS in all phases of Installed Base Management
© ABB Group March 25, 2010 | Slide 26
ServIS status in ABB
§ Use statistics§ 4000 + registered user
§ 315 active users
§ 575,000 installations (Number of products and systems)
§ 46,000 customer sites - 25,000 customers
§ System is operated and supported by GF-IS§ Today 5 permanent full time employees
§ Implementation in 4 divisions - PA, AP, PP & PS
Active Users
0
50
100
150
200
250
300
350
400
Jun-
06
Aug
-06
Oct
-06
Dec
-06
Feb
-07
Apr
-07
Jun-
07
Aug
-07
Oct
-07
Dec
-07
Feb
-08
Apr
-08
Jun-
08
Aug
-08
Oct
-08
Dec
-08
Feb
-09
Customers & Sites
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
Ap r-07May -07
J un-0 7Jul-07
Aug -07Sep -07
O ct-07
Nov-07D ec-07
J an-0 8
F eb-08M a r-0
8
Ap r-08May -08
Jun -08Ju l-08
Aug -08Sep -08
O ct-08N ov-08
D ec-08Jan -09
F eb-09
Companies
Sites
Users
Users
Sites
© ABB Group March 25, 2010 | Slide 27
Continued development of Installed Base Intelligence
§ Soon to come
§ A new interactive analytical tool § ServIS Extranet for our customers
© ABB Group March 25, 2010 | Slide 28