Life Cycle Solutions. Lowering Equipment Cost Increasing Plant Output

Transcription

1 Life Cycle Solutions Lowering Equipment Cost Increasing Plant Output

2 >> Life Cycle solutions If you had... {... A database of installed equipment that was continuously updated with each new design, purchase, installation, repair or upgrade... Access to live inventory levels across the supply chain and were confident you had access to the inventory needed to support the operation... The ability to scan a bar code on installed equipment and know it s current status, maintenance history, performance information, repair parts database and associated inventory levels... Instant access to reliability (KPIs) like mean time between failure, total cost of ownership and bad actors, to quickly identify and solve unreliable and inefficient systems... The knowledge to decide if you should repair, replace, or upgrade a system upon failure... would it help you to lower equipment costs and improve plant output? Cost Reductions: Lower Purchasing Costs Reliability Improvements Lower Inventory Cost Quality Repairs to OEM Standards Lower Energy Cost Warranty Recovery Effective Repair / Replace Decision Making Data Output improvements: Higher Overall Equipment Effectiveness (OEE) Bad Actor Elimination Less Downtime Workforce Skills Improvements Better Design/ Application 2 >> Life cycle solutions

3 equipment life cycle << Initial Price A Fraction of Total Cost 90% Operating Cost : 4% The initial purchase price of a pump is only a fraction of the total cost of ownership. Maintenance, energy, operational and downtime costs are your real concerns - year after year - over the life of the equipment. Life Cycle Solutions New equipment and designs engineered to: Meet production requirements, maximize reliability, Initial Cost: maintainability 10% and efficiency View and optimize inventory levels (on site, sister facility, vendor) to support operations Scan a barcode for maintenance history, bill of material, associated inventory levels, KPI s, etc. Know if equipment should be repaired, replaced or upgraded Operation: upon 9% failure Life cycle solutions << 3

4 p >> design and sourcing : 4% During the stage ITT will: Case Study: Plant Optimization : 4% Maintenance & Conduct a site assessment to evaluate current practices, procedures, systems and workforce culture to guide the development and specific requirements of the and Logistics implementation. Enter all information for all equipment into AiMS, ITT s collaborative asset management system using existing client systems information and link all specification, purchase and performance data from vendor data files to set the stage for all future activity with each item. Perform an installed base evaluation to validate all existing equipment data is accurate and included in the AiMS system. Provide design support, when required, for all new designs, upgrades and modifications. A multibillion-dollar supplier of basic and specialty chemicals In the first four years after implementing ITT s comprehensive plant optimization service, mean time between failure (MBTF) for pumps has improved 71 percent, netting $1.5 million in operations and maintenance savings. Environment: >> Inventory 7% During the Inventory stage ITT will: : 4% C c C d Cp C p C C m a Maintenance Repair: Maintenance & Enter all existing inventory data into AiMS. Compare all existing inventory items to vendor recommendations to ensure optimum levels of components, subassemblies, complete units and consigned items are available to support daily operations. Establish a process to track use, cost and ensure replenishment for all inventoried items. Provide timely standard and custom inventory reports to management. Identify abnormally high use and premature failure of inventoried items and work with local maintenance and reliability teams to resolve root cause or initiate warranty claim. Case Study: Energy Efficiency A large paper manufacturer with over 1,000 centrifugal pumps an Energy Performance Services assessment yielded recommendations for 23 pumps, with a projected savings of $1.1 million in energy and maintenance costs on a capital investment of $591, >> Life cycle solutions

5 Initiate Life Cycle Asset Management : 4% During Operation ITT will: Maintenance & OPeration << Case Study: Performance Services Work with maintenance and operations teams to identify and resolve bad actor equipment issues. Monitor the need for and provide ITT resources Asset when Tracking required for: An oil refinery with a capacity of 120,000 barrels of oil per day ITT conducted a root cause analysis (REsolve) on 30 bad-actor pumps. Over two years, repair costs have been cut by 75 percent and emissions by 95 percent. Energy Performance Audits and Improvements Machine Health Strategy Development and Monitoring Upgrades Recommendations and Designs for Obsolete, Outdated or Inefficient equipment Maintenance, Operator and Management Training Requirement Root Cause Failure Analysis Support Maintenance & Case Study: Plant Optimization A company producing atmospheric gases through cryogenic distillation ITT design engineers refitted a Goulds 3196 pump to function as a hydroturbine, capturing depressurized water. This modification allows 70 kw of previously lost power to be captured and used, resulting in an energy savings of $24,000 per year. When Repairs are required ITT will: Develop process to manage logistics for equipment to repair location and back into inventory. Make repair/replace/upgrade recommendations Ensure equipment is remanufactured in accordance with OEM specifications Capture repair details and likely cause of failure to facilitate Root Cause Analysis Assess Warranty for all repaired items Track the following for each repair: Repair Details Repair Cost Mean Time Between Failure Mean Time to Repair Shipping Cost and Duration C p C o C c : 4% C d Cp C C m Database a of Equipment Operation: Design 9% and Sourcing : 4% C c C d Cp C p C C m a repair Maintenance & << Life cycle solutions << 5

6 >> ITT Solutions AiMS Client AiMS is a collaborative workspace to share data, report findings and manage projects. Elements of Life Cycle Solutions New Equipment, Parts & Subassemblies Installed Base Evaluation Design Support Inventory Optimization Inventory Management Quality and Standards Troubleshooting Root Cause Failure Analysis Warranty Management Reliability Improvement Energy Performance Machine Health Monitoring Upgrades Training ITT s performance services may be deployed as stand-alone or integrated solutions. ITT Performance Services teams provide an array of services focused on reducing Total Cost of Ownership (TCO) and increasing plant output. Our extensive skills and knowledge are deployed to maximize the potential of your assets throughout their life cycle, creating real and sustainable economic value for your operation. ITT offers a comprehensive range of solutions customized to help clients maximize the life and efficiency of their assets. 6 >> Life cycle solutions Database of Equip Performance Ind

7 ITT Solutions << { Life Cycle Solutions Components and Logistics Link vendor data to AiMS and customer (CMMS, ERP, etc.) Plant Procedure Mapping Inventory Analysis Installed Base Evaluation System training and startup Reporting and Analysis Includes equipment and 3 seats On-Site Specialist On site support and reinforcement of and Logistics (T&L) process Technical support for pump systems Support and drive reliability initiatives Institutionalize best practices Ongoing data mining and gap analysis Team leader for other Plant Performance services ITT Contract Repair contract Power end program Other Plant Performance Services Pump and parts contract Strategic Account Agreement A La Carte Pricing Every component and option is priced as a line item Contract Pricing Pump / part / repair cost reflects included services Performance Contract Shared risk and reward, pay based on performance } Pricing Options Life cycle solutions << 7

8 Contact ITT Performance Services: Visit our Web site at Form BLCS 03/ Goulds Pumps, Incorporated A subsidiary of ITT Corporation