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ABB Ability™ Performance Optimization for QCS

Improve control utilization, sensor stability and process variability.

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Overview
Application
Methodology

The ABB Ability™ Performance Optimization for QCS identifies, classifies and helps prioritize opportunities to improve product quality, measurement and control health, and control utilization.

Performance Optimization for QCS uses non-stop data collection and analysis to transform raw data into actionable information.

This service quickly pinpoints issues to ensure optimal performance of equipment and systems.

Data is classified based on specific key performance indicators (KPIs) to provide a list of problematic items that are prioritized based on severity, process area, criticality and/or financial impact.

KPI’s include the following:

Control utilization

  • Shift reports are analyzed to determine the percentage each control is used per shift. Usage then is measured against the optimum utilization for a specific control to help reduce shift to shift variability.

Sensor Stability

  • Standardized sensor values are monitored and compared to peak operating conditions. Trends are analyzed to determine if preventive maintenance should be scheduled to maintain high sensor performance and avoid lost production.

Reel Variability

  • Reel Variance Partition Analysis (VPA) information for each grade produced is monitored for total variation, cross direction variation and machine direction variation against industry standards.

ABB Ability™ Performance Optimization for QCS Channel analysis leads to more informed, more responsive decision making, resulting in better performance and utilization.

ABB Ability™ Performance Optimization for QCS identifies, classifies and helps prioritize opportunities to improve product quality, measurement and control health, and control utilization in your plant.

ABB Ability™ Performance Optimization for QCS, uses non-stop data collection and analysis to transform raw data into actionable information, quickly pinpointing issues so you can ensure optimal performance of equipment and systems.

Features

  • Automatic, non-invasive data gathering with ABB’s proprietary data collection tool
  • Advanced, patent-pending technologies provide continuous analysis of Key Performance Indicators (KPIs)
  • On-site or remote access for customer personnel and ABB support
  • Twice-a-year performance analysis by ABB experts to identify issues and recommend performance, utilization and stability improvements
  • Configurable email alerts are supplied when KPIs are outside site-specific thresholds
Benefits
  • Improves production uptime by ensuring QCS stability through preventive maintenance identification
  • Accelerates problem solving through real-time visualization and analysis of sensor stability, control utilization and process variability
  • Saves time and money with automatic grouping and quick analysis of production quality data by grade
  • Reduces response time and travel expenses by providing remote access to ABB experts for troubleshooting
  • Establishes a solid foundation for continuous improvement, including higher availability, increased production and improved quality

Performance Optimization for QCS follows an advanced services, three-step methodology—Diagnose, Implement and Sustain—which improve control utilization, sensor stability and process variability.

Step 1: Diagnose

Performance Optimization for QCS uses non-stop data collection and analysis to transform raw data into actionable information. This service uses comprehensive data mining techniques, proven key performance indicators and standard operational values modules to access and analyze process performance.

Step 2: Implement

Based on a thorough analysis, an implementation plan is developed by ABB and the customer through a collaborative review. After the plan has been agreed, improvements can be delivered incrementally or all at once. Phased implementation ensures that process and equipment changes can be made and maintained with steady progress toward performance goals.

Step 3: Sustain
Performance Optimization for QCS provides 24/7 monitoring capabilities to sustain benefits achieved after recommended changes are made to help to ensure process performance remains at peak levels. Data collection and continuous or periodic monitoring help to develop operational trends to allow early detection of anomalies and planning for servicing equipment.

Sustaining Improvement
Available as a subscription service, Performance Optimization for QCS offers substantial financial value by providing access to ABB experts without losing time or requiring travel costs to get service experts to site.

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