A dedicated Automation Services offer for your installed base

marblefreedomAI and Robotics

Nov 14, 2013 (3 years and 10 months ago)

115 views

A dedicated Automation
Services offer for your
installed base



2

... We are in a challenging environment


Economical constraints


budget restrictions


inventory reduction


equipment life span extension


Regulations


safety


environment


Human resources


staff reduction


loss of technical competences


Technology


increasing complexity


new solutions availability



3

Our Automation Services offer

helps you to:

Anticipate
risks

Improve
your installation performance

Keep control
of your investments






4

Helps you to anticipate risks

Reduce
complexity
, and
optimise your
maintenance
plan

to reduce the
impact in case of
failures

Check

and
improve

the
design

of your
automation system
to reduce the
number

of failures

Define the right
methodology

and technical
solutions to
limit
the risks

during the
modernisation
project



5

Improve your installation performance

Get our
expertise

to
identify
functional
limitations

and
have
improvements
recommendations

Standardise

a
modernisation
solution
and
deploy it in

multi
-
locations

Increase
flexibility

and
safety

with
advanced
automation
solutions



6

Keep control of your investments

Prioritise

and
optimise

your
investments for a long
-
lasting system

Maintain

legacy equipments with
a reduced maintenance budget

Find
innovative solutions

to
found your modernisation projects



7

A complete Automation Services offer


to meet your needs during the two phases of your equipment lifecycle

Operation

Modernisation



8

Spare parts and repairs

What we
offer

Spare parts and repairs offers are giving you everything you
need to get your equipment back to work as quickly as
possible in the case of failure or malfunction

Delivery


Supplying tested, certified and compatible spares


Reconditioned parts available for certain requirements


Setting up of a spares stock on your premises

Your benefits


Limited machine breakdown time


Manufacturer quality original parts


Special prices for reconditioned parts


Spare parts or repairs availability up to 10 years after parts
are discontinued



9

Maintenance contracts

What we
offer

Improving and guaranteeing the reliability of your installations
in the long term

Delivery


Direct telephone access to an expert


Updating of software and updating to a website


Setting up of a spare parts stock on
-
site or off
-
site


On
-
site assistance in a given timeframe


Installed base audit


Taking account of your modernisation projects in a contract

Your benefits

Having a global and updated vision of the installation
enabling:


Anticipation of technical risks related to obsolescence


Control of maintenance costs


Scheduling of necessary modernisation projects


Benefit from the latest technical innovations



12

Training

What we
offer

Giving your teams the necessary competences to:


Operate better and make operations secure


Optimise the efficiency of installed equipment

Delivery


50 training centres throughout the world


Trainers who are experts in industry and teachers


Training courses:



catalogue, customised or tailor
-
made



on your sites, in our centres, e
-
learning

Your benefits


Assessing your precise training needs according to the level
of your teams


Optimised your use of competences


Training given at your rhythm, in line with your habits



14

Consultancy and expertise

What we
offer

A structured approach to


Better identify and qualify improvements opportunities


Secure the technical points of a project


Master deployment

Delivery


Diagnosis & recommendations


Feasibility & specifications studies


Project management support

Your benefits


A clear vision of the actions to be engaged


Our commitment on results of solutions we are studying
and implementing


Costs reduction and same quality level in case of
multi
-
site and international deployments



16

Consultancy and expertise:
a zoom on the
M2C

offer



M2C

means Maintenance and Modernisation Consultancy



M2C

is one of the Schneider
Electric
consultancy offer but
not the only one



M2C

is using unique methodology and tools to deliver
recommendations for the benefit of the customer



17

Typical customer’s contexts for the M2C
offer


Organisation
changes


Know how losses due to retirement of key people


A new maintenance manager integrate the service


An outsourcing policy is engaged


Performances issues


New maintenance budget constraints


Major failure with production losses


Repetitive and uncontrolled failures


Performances limitation


Technology and regulation evolutions


Automation components/system obsolescence


Implementation of safety regulation


M2C


Other

consultancy

offers



18

A four steps methodology

Preparation

Data
collection


without


disturbing
the
production

Analysis
with


indicators

construction

Elaboration of


the final

recommendations

Step 1

Step 2

Step 3

Step 4



19

Preparation for a better alignment


Job perimeter


The whole installed base including all the new process
lines


Stocks and competences inventory


Intervention conditions


Safety rules have been delivered to Schneider
Electric

team


Intervention is planned on Sept. 12th


Mr Mohammed from the maintenance department will be
part of the inventory phase


Report will have to be delivered by Oct. 10th in our
premises


Mr Saeed, plant manager will be present


Site context: (for recommendations)


Not a clear vision of the future investments


Maintenance quality has to be improved first

Execution
phases

PREPARE

COLLECT

ANALYSE

REPORT



20

Installed base inventory

Stock & Competencies
Inventory

Automatic installed base data collection

Execution
phases

PREPARE

COLLECT

ANALYZE

REPORT



22

Three items to drive the analysis


Reduce the impact in case of failure:


Do you have the right software and spare parts?


Is your team competent enough to maintain?


Are your maintenance procedures well adjusted?


Reduce the number of failures:


Is the design of your Automation system well done?


Improve the performances:


What is the obsolescence level of your Automation
assets?


Where are the performance limits?


Are there some critical improvements to manage
urgently?

Execution
phases

PREPARE

COLLECT

ANALYSE

REPORT



23

April, 2009

Maintenance procedures

Competencies

Stock & software coverage

Reduce the impact in case of failure

Execution
phases

PREPARE

COLLECT

ANALYZE

REPORT

Stock coverage is low for
critical machines.

Strategic spare parts for
984 Modicon PLC &
Lexium drives have to
be considered as the
first priority

The obsolescence level for
984 Modicon PLCs is high



24

Automation design

Reduce the number of failures

Execution
phases

PREPARE

COLLECT

ANALYSE

REPORT

The cabling of the Modbus plus &
Ethernet networks aren’t well done

The Ethernet ring load is too high,
as well as the collision rate

Environment conditions
have to be fixed for the
filling up line

A lot of major mistakes
has been identified



25

Improvements

Limitations

Reduce

limitations & improve performances

Execution
phases

PREPARE

COLLECT

ANALYSE

REPORT

A limited number of
major improvements

Majors Limitations : PLCs
memory limit, network
obsolescence components,
network capabilities, and
increase of packing machine
performances (motion control)

Majors improvements : Safety compliance for general conveyor, rationalization
/standardisation of the PLCs program, and energy efficiency with soft starter to limit
peak current on compressors, and variable speed drives on cooling pumps.



26

Report presentation

Execution
phases

PREPARE

COLLECT

ANALYSE

REPORT

Maintenance and Modernisation
Consultancy



27

STEP 2

STEP 1

Action plans proposal

Execution
phases

PREPARE

COLLECT

ANALYSE

REPORT

Main action plan Step 1 (Now)

Training

plan

Modernisation
plan

Contract

Expertise

Training of 2
people

Partial migration of
2 PLCs

3 years technical

support

Network
certification

Work done by
your team

Safety: in deep
assessment

Technical

priorities to

manage


Fix old Modicon
PLC stock
coverage for the
most critical
machines


Become
autonomous for the
maintenance of the
new bottling line


Engage an action
plan on PLCs
applications backup


Engage action
plans for the
Ethernet network
(Ferment process)


Engage a
performance plan



28

STEP 1

STEP 2

Main action plan Step 2

Execution
phases

PREPARE

COLLECT

ANALYSE

REPORT

Main action plan Step 2 :
S1 +12 months

Training

plan

Modernisation
plan

Contract

Expertise

Training of 2
more people

3 years technical
support

Extension with
network preventive
maintenance

Full
migration
of 2PLCs
(done by
your team)

Technical

priorities to

manage


Fix old Modicon
PLC stock
coverage for the
most critical
machines


Become
autonomous for the
maintenance of the
new bottling line


Engage an action
plan on PLCs
applications backup


Engage actions
plan for the
Ethernet network
(Ferment process)


Engage a
performance plan

Safety
recommendations
implementation
and energy
efficiency



29

M2C done
in one of the Affiliates of SABIC


Two Plants
with more than
40 PLC

Systems which have more than
2800 items
.


Many of the maintenance crew members are not familiar with using Schneider’s automation
legacy products.


Bad visibility
on installed Process
communication networks
.


Each Plant
has different Automation standard
. Need Standardization.










A 4 days on
-
site data collection without disturbing the production


A report elaboration with three main recommendations


Actions to be started immediately


Actions to be done in the next 12 months.


Action to be done in the next 24 months.

A global diagnosis & recommendation to define
the improvement avenues for the two Plants



Customer needs

Our services solution



30

M2C done in one of the Affiliates of SABIC


Precise
actions

including costs, implementation schedule,

and savings


The customer is able to
manage by itself

the
recommendation plan


We are committed on both
technical solutions

and
implementation


Customer needs met



33

Project management

What we
offer

We have tools, methods and a strong experience in
project management to reduce risks and bring you better
performances.

Delivery

A global Automation & control system fitting your
requirements in terms of performances, costs and quality.

Your benefits


Commitment on results in case you need a short and
guaranteed production downtime


Optimise costs and quality thanks to our project
management tools and methodology


Partnership in the long term beyond the Modernisation



34

USA : Modicon
migration

France : Scada
migration

Germany : AEG &
Modicon migration

France : Telemecanique
PLC & DC drives

Global competence centres will support
by their expertise your projects



36



Our budget was limited, and we
needed to continue to maintain
the oldest products included in
the architecture.

A customized contract mixing
maintenance &
modernisation

was the best solution.”

Customer feedbacks



37

A dedicated services offer to your automation
installed base

Thank You for your attention




Q&A