Accenture Plant and Automation Solutions

Build and operate plants in a reliable, safe and cost-effective manner

Achieving high performance with Accenture Plant and Automation Solutions

Challenges facing assetintensive companies

In recent years, it has become increasingly difficult for asset-intensive companies to build and operate plants and assets in a reliable, environmentally friendly, safe and costeffective manner due to issues such as:
Lesser-developed countries pose their own unique labor challenges. Operators often find that the local talent pool has limited skilled workers. Those who are skilled are demanding salaries considerably higher than local cost-of-living standards.

Let Accenture help you overcome these and other challenges with the Accenture Plant and Automation Solutions.
To help your company resolve short-term challenges and position for high performance in the long term, our vendor-neutral solution addresses key areas such as: Engineering, project and data management Core operations Environment, health and safety Industrial automation capabilities We also provide back-office and other enabling services such as operational support, data management, procurement and warehouse, and learning services, to name a few.

Complexity of capital projects

Due in part to global demand and the emergence of new technologies, capital build projects are growing more complex. In the energy industry, for example, ultra-deepwater exploration and unconventional oil and gas production are technically complex projects. Across industries, we see that project complexity is influenced by other factors such as geography (e.g., harsh, remote locations) and the local political environment.

Aging assets
It is not unusual for companies to operate with equipment that was originally installed two or more decades ago. While some components have been updated, the heavy use of aging assets has brought the issue of asset reliability to the fore.

Workforce trends
Labor demand is outpacing supply. In developed countries, the demographics of an aging population means that experienced employees are expected to retire over the next several years. Meanwhile, younger workers and recent graduates (with engineering skills) have different expectations about work and are showing less interest in pursuing careers in asset-intensive industries.

Financial markets
While there are signs of global economic recovery, everyone continues to keep their eye on the resurgence of financing, market liquidity and activity in mergers and acquisitions.

Did you know? Accenture has almost 300 industrial engineers distributed in delivery centers in Brazil, India, South Africa and Spain. Our capabilities extend from enterprise resource planning (ERP) through instrumentation.

Engineering, Project and Data Management

In Accentures experience with capital build programs, we see two key trends emerging.
The first is that due to heavy usage of plants and the age of some assets, significant investments in infrastructure are neededan estimated $26 trillion between 2007-2030.1 This is a considerable investment for companies with fluctuating profit margins and reduced operating expenditures (OPEX). A high level of investment is expected to occur in every major geography and be especially intense in offshore oil and gas, refining, mining, nuclear and renewables industries. Second, capital project owners often have not developed the necessary in-house skills to effectively manage multibillion-dollar, multiyear capital projects. Complex capital build projects often involve multiple stakeholder groups, including contractors, subcontractors, alliance partners and suppliers. The number and size of capital expenditure (CAPEX) projects has increased the risks for capital project owners.

Our solution
Accentures engineering, project and data management capability includes industry-leading practices for developing a capable project delivery organization. Our solutions emphasize governance, proven project management disciplines and reusable tools for collaboration and monitoring.

Potential benefits to you

Improved overall capital project delivery, efficiency and asset operability. Increased cost control through enhanced data/information transparency. Better integration and integrity of engineering and project systems. Improved reliability and efficiency of data handling between engineering, procurement and construction (EPC) companies and project owners. Better support of data acquisition, integration, cleansing, integrity and contract compliance through establishment of a nonintrusive data service. Reduced construction schedule delays resulting from underplanned and underestimated activities (e.g., licensing). Improved identification/mitigation of risks early in the projects. Increased return on capital investments by combining industryleading program management practices with reusable asset management tools. Enhanced project planning and execution through improved sourcing, contracting and claims management. Expedited decision-making processes with more accurate reporting.

1. New Energy Realities - WEO Calls for Global Energy Revolution Despite Economic Crisis, International Energy Agency press release, November 12, 2008, http://www.iea.org/press/pressdetail.asp?PRESS_REL_ID=275.

Did you know? UniStar Nuclear Energy LLC has named Accenture as one of its key partners. UniStar is working with Accenture to create an IT platform to support the life-long data needs of a nuclear plant.

Services we provide
Process and IT Infrastructure
Helps companies create, modify, share and store information during the entire life cycle of a complex capital projectfrom licensing, design, procurement, construction, and commissioning through operations and maintenance. Enables data and information exchange between engineering procurement construction (EPC) suppliers and owners for the plant design and construction phase. Provides project life-cycle data management, configuration and change management (for single plant and fleet), change impact assessment, intra- and intercompany collaboration, multicompany interoperability, workflow and notifications, and connectivity standards.

Project management
Enables evaluation and implementation of project structure, governance and stage-gate management processes necessary to deliver large capital projects. Includes tools and methodologies for assessing the companys current competencies and creating the appropriate recruiting and retention plans.

Intermediary data services

Provides the staff to manage the data infrastructure as well as conduct data management activities including data acquisition, integration, cleansing, integrity and contract compliance. Covers data acquisition, integration, cleansing and integrity as well as contract compliance activities. In addition, Accenture brings its management consulting skill set including strategy, planning, supply chain management, and enterprise solutions to complement these core services.

Core operations
A number of maintenance trends (focused on improving reliability) are emerging in assetintensive industries.
Historically, asset-intensive companies have kept a focus on maintenance cost reduction. The result, however, has been a reactive (break-fix) approach to maintenance with short-term priorities. In order to achieve business performance goals and objectives, companies strive to operate and maintain their plants and asset investments in a highly efficient, effective manner. This quest for performance means companies need to decrease asset downtime and costs. One way to reduce the investments in your assets is by extending their life (through asset life-cycle management). Similarly, rationalizing and consolidating maintenance suppliers can assist your objectives. We find that the use of remote diagnostics and smart monitoring technology is key to adopting a proactive maintenance approach. Asset management analytics and information capabilities improve decision-making and intelligence. For upstream energy companies, our integrated oilfield solutions can help drive value in core operational activities (in areas such as facilities, reservoir and wells). For refiners, Accentures core operations solutions can help you run safe and sustainable operations, monitor performance, proactively maintain assets, and achieve plant-to-business integration using automation and industrial IT. Additionally, Accentures integrated optimization approach for the hydrocarbon supply chain can help you achieve the most optimal operations from crude to retail (to realize the highest margin in most dynamic market conditions).
6

Our solution
Accentures core operations solutions consist of a combination of plant maintenance and reliability, production optimization, supply chain optimization and the Accenture Plant Performance Solution for upstream. Together, our solutions help our clients achieve better asset uptime, enhance production, improve resource optimization, strengthen maintenance planning, improve costs and facilitate safer operations processes.

The Accenture Plant Performance Solution

The Accenture Plant Performance Solution provides plant information technology that presents the right information at the right time, to the right people. It provides an integrated architecture to enable optimized, collaborative operations. Accenture has solutions that address the digital oilfield, the smart refiner, as well as our proven platform for plant performance and management for generation (fossil and wind).

Potential benefits to you

Reduced equipment failures Identification of equipment most important to plant production Optimized CAPEX through improved planning Enhanced information on equipment health Improved workforce priorities and effectiveness Coordinated feedstock supply chain for optimal planning and scheduling Increased production output

Did you know? Accenture is an international company, with offices or a business presence in locations such as Aberdeen, Abu Dhabi, Bangalore, Beijing, Calgary, Doha, Houston, Jakarta, Kuwait City, Lagos, London, Luanda, Moscow, Perth, Rio de Janeiro, Seoul and Stavanger.

Services we provide
Maintenance and reliability solutions
Accentures maintenance and reliability solutions help deliver increased reliability and maintenance effectiveness and support the journey to maintenance excellence. Equipment strategies development Helps deliver the most appropriate maintenance regime, balancing total cost of failure versus maintenance costs. Maintenance and supply chain processes optimizationHelps enable the effective use of technicians on the right activities with the required tools and parts necessary to complete the work. Asset systems and information managementFocuses on implementation and integration of systems such as maintenance, reliability and mobile solutions. Accelerating and sustaining approachAddresses optimized maintenance organization and capability, and maintenance improvement through techniques such as Lean Six Sigma. balance data reconciliation (MBDR) and yield account management (YAM).

Supply chain optimization

Supply chain optimizationCaters to optimization of all move, store and process commercial activities of an industryfrom the point of feedstock acquisition until the finished product reaches the end user. Forecast economics and pricing Improved customer end pricing and true price of stored inventory. Forecast and manage demand Limited human intervention, reduction of stock-outs/safety stock and intermonth scheduling constraints. Envelope plan and schedule developmentSchedule to optimized plan, intermediate stream optimization and intra-envelope synchronization. Planning, scheduling and blending modelsInclude crude assay management, crude valuation, allocation optimization and arrival sequence optimization.
7

Production optimization solutions

Production optimization is Accentures approach to helping our clients increase throughput and product yield, and reduce operating costs and energy through: Production performance managementImproved analysis and understanding of production performance. Advanced process controls/real-time operationsReduced barriers between field operation and asset control, by enabling real-time data availability. Energy managementA holistic approach to energy efficiency including regulatory management, plant optimization and upgrade technology. Yield account management (YAM)A proven approach to mass

Environment, health and safety

Environment, health and safety (EH&S) is a major priority and a big undertaking for assetintensive companies.
EH&S efforts help to reduce losses, increase results and bring a reliable image for companies in different markets around the globe. Governments worldwide are moving toward enacting environmental legislations for carbon abatement. These impending regulations will require new manufacturing techniques and management processes to guarantee carbon emissions reduction. In addition, resources and more restrictive safety and environmental requirements and legislation are becoming a concern to asset-intensive companies. Due to water scarcity and reduced water quality, for example, water management is increasingly incorporated in the design and operation of manufacturing facilities. Licenses and permits related to design, construction and operation of assets can become a bottleneck, leading to increases in CAPEX, as well as impacting time, scope and technology applied to the asset. Safety, too, is a multifaceted issue. Promoting a safe and healthy environment in the workplace is a top priority. Process safety is particularly emphasized as companies strive for zero fatalities and incident-free operations. In the past 10 years, the incident frequency rate has decreased enormously in different markets and industries; this despite more complex processes and operations and bigger plants and assets. The challenge can be to understand where is the EH&S maturity level and how to leverage new EH&S standards for your organization. In the publics perception (and in some cases, in the courts decision), companies are considered responsible for the health of the local community. And in recent years, manufacturers are not only responsible for their own operations, but the safety of products and services from far-flung suppliers in their supply chain. In many countries, different companies consider this in their contractor agreements, with EH&S clauses to reach minimum requirement conditions for contractors employees. EH&S management agreements for contractors can also be a great challenge for organizations.

Our solution
Our EH&S offering targets environment, health and safety concerns for asset-intensive companies engaged in exploration, manufacturing, production, and/or plant operations

Potential benefits to you

Sustainability efforts that focus on more than just compliance. Deliver business value in terms of increased revenue, improved costs, lower risk and long-term brand value. Better management of regulatory compliance and operational risks Cost reduction through better planning and foresight (e.g., in insurance premiums) Higher productivity and greater quality control Developing the capacity to communicate a green image that will positively impact employee retention and sales Progression through different EH&S phases, leveraging EH&S capability models to strengthen safety culture Improved response to stakeholder demands and better ability to meet internal and external commitments

Did you know? Accenture announced the first deployment at Marathon Oil of the Accenture Life Safety Solution, a wirelessenabled gas detection system that helps protect workers in potentially hazardous environments. The solution breaks new ground by combining Wi-Fi and location-based technologies with gas detectors to allow companies to remotely monitor incidents in locations previously not suited for wireless networks.

Services we provide
Environmental impact
Working with our comprehensive sustainability framework, we help our clients measure and reduce their carbon footprint, make operations more energy efficient, and reduce waste and emissions. We team with them to develop land-sustainability policies and optimize water usage. We help them create green supply chains and sustainable procurement processes and we collaborate with them to measure, manage and monitor sustainability performance at the business unit, geography, process and enterprise level. Our services include: Emission trading Trading and risk management Waste management and sourcing Energy management services Environmental impact analyses REACH compliance Product stewardship Product life-cycle management

People, plant and process safety

We provide systems integration and consulting services that include organizational change management, development of procedures and documentation and development of a monitoring approach for third-party certifications. We also help our clients with: Safety critical element identification Risk analysis Process safety management Wireless location technology Permit to work systems

surveillance, fit-to-work procedures and epidemiological surveys. Our services in this area include: EH&S processes and systems assessment Performance reporting systems EH&S functional excellence Compliance reporting

EH&S governance and culture

We help effectively coordinate, manage and deliver health services across the company. In the end, we enable companies to have a comprehensive health function that addresses the full range of occupational-health, industrialhygiene and incident-management activities, including: Safety culture assessment Cultural and behavioral change Change management EH&S governance and compliance EH&S accounting
9

EH&S performance management

Accenture provides a range of services that enable companies to strengthen and streamline the employee health function. Working closely with clients we standardize health-management processes, from health risk assessment, exposure measurements and incident management to medical

Did you know? Accenture has developed a powerful network of solution providers and technical partners. We work closely with more than 150 technology market leaders to complement and extend Accenture's solutions and capabilities. A few of these solution providers and technical partners include: AspenTech, IBM Maximo, Microsoft, Oracle, OSIsoft, PowerSim Software, SAP, Siemens PLM and SmartSignal.
Note: The above names are registered trademarks of the respective companies.

10

11

Industrial automation capability

Companies are now recognizing the opportunity to take advantage of converging industrial IT with corporate applications as an important lever to raise productivity.
Numerous investments have been made in IT, particularly in ERP systems. But as new technologies are introduced and the population ages, many companies have a challenge with knowledge retention and developing new ways of cooperating across physical boundaries.

Manufacturing Execution Systems (MES)

Accenture's Manufacturing Execution Systems (MES) capability helps companies go beyond linking the top floor and the plant floorwe help companies truly integrate manufacturing and the business. Our approach helps companies improve speed and minimize risk during implementation, and capitalize on the increased efficiency and responsiveness offered by MES. We collaborate with our clients to create comprehensive strategies for designing, implementing and using MES in ways that fit their specific business. We help establish longterm business goals for MES, identify opportunities to drive business performance, and create plans for using MES to make the manufacturing environment an integral part of the overall business. Accenture also collaborates with companies to execute those plans and strategies. We address not only technology, but also the people, processes and organizational factors related to MES implementations. We assess existing processes and systems, and identify opportunities where standardization can bring greater efficiency and consistencyand where innovation can bring performance improvements. And we design and implement new processes for automatically gathering and tracking real-time performance in detail. Accenture's approach to MES also focuses on managing the transition to the new environment to produce lasting, meaningful change. We work with clients to enlist the support of top management, communicate with stakeholders and motivate, train and empower peopleall of which helps ensure that the organization is prepared to use and succeed with the new MES-enabled processes.

Helping Metro de Madrid increase service levels

Metro de Madrid, the third-largest metro system in the world, has successfully introduced a program to transform its maintenance operations and provide higher standards of transportation services. To meet Metro de Madrids operational goals, Accenture implemented a new operational maintenance model and designed a technology infrastructure to manage real-time installation of equipment (such as elevators, escalators, ticketing and turnstiles). Since the launch of the program in June 2006, Metro de Madrid has realized a range of benefits including: Putting into service about one-third more equipment and facilities without deteriorating the quality of service. The costs of implementation were also controlled. Increase in positive customer experience due to real-time availability of the state of services offered.

Our solution
Accenture's industrial automation capability helps companies achieve high performance by enabling plant-to-business integration. Our solutions connect and synchronize the shop floor and the C-suitehelping companies turn production data into useful information through an integrated application of technology in operations.

Potential benefits to you

Vendor independence Core process control engineering knowledge Methodology to run multiplant, multicountry programs Ability to incorporate talent and performance management (TOP) capabilities into industrial projects Ability to transform data into knowledgeintegration of operational and business systems delivers critical insights from the shop floor to business systems for better decision making Optimized manufacturing process for improved productivity, quality and greater efficiency enables operational excellence in a sustainable manner
12

Did you know?

In July 2008, Accenture acquired ATAN, a privately held provider of industrial IT and automation solutions based in Brazil. The new service offering expands Accentures automation and industrial information technology (IT) services capabilities.

Services we provide
Industrial and automation capability solutions
Automation technology Instrumentation, power, control and supervisory systems in green and brownfield environments Turnkey solutions, systems specification and configuration (SCADA, PLC, UTR, DCS, radio frequency, data communication, etc.) Startup and commissioning, training, and technical assistance Production management Manufacturing execution systems (MES) Labs information management systems Production information management systems Plant-to-business systems integration Mobile solutions Process optimization Control loop management Intelligent operations center design and implementation Brownfield optimization/ revitalization Variability reduction, asset management and optimization, and overall equipment effectiveness

Special solutions
Nonferrous metallurgical industries Supervise, control and manage the production process of nonferrous metals (aluminum, zinc, nickel, copper) Railway operation Railway automation master plan, after-sales support for new equipment, railway operation management system, hardware and software platform to monitor and control locomotives integrated with the operation management system.

13

Why Accenture?
Delivering value to clients
We bring the breadth and depth of our global scale to our clients. We have experience and deep industry knowledge.

Accenture global facts

Accenture has offices and operations in more than 200 cities in 52 countries. Accentures clients span the full range of industries around the world and include 96 of the Fortune Global 100 and three-quarters of the Fortune Global 500. Of Accentures top 100 clients, based on revenue, 99 have been clients for at least five years and 91 have been clients for at least 10 years. Accenture has more than 181,000 people serving clients in more than 120 countries.

We place a heavy emphasis on longterm relationships. We work where you work. We understand your business and your culture. We dont just talk about the need for new solutions; we are at the forefront of developing them.

Accenture spent $495 million on research and development in fiscal year 2009. Accenture Technology Labs, the dedicated technology research and development (R&D) organization within Accenture, has been turning technology innovation into business results for more than 20 years. The Labs create a view of how technology will shape the future, and invent the next wave of cutting-edge business solutions. The Accenture Global Delivery Network comprises approximately 80,000 highly skilled professionals at more than 50 delivery centers around the world.

We use common methodologies, tools and metrics to deliver high-quality, consistent services.

2. As of fiscal year ending August 31, 2009.

14

Contact us
We help companies become highperformance businesses by drawing on our deep industry experience and the findings from our High Performance Business research. To learn more about how Accenture can help your assetintensive company on its journey to high performance, visit us at www. accenture.com or call us at +1 312 737 7909 or toll-free in the United States and Canada at +1 888 688 7909.

15

About Accenture Plant and Automation Solutions

Accenture Plant and Automation Solutions is a suite of offerings designed for asset-intensive companies across industries such as metals and mining, chemical, pulp and paper, oil and gas, and utilities. Our offering comprises solutions for engineering and project data management, core plant operations, environment, health and safety, enabling services, and industrial and automation capabilities. We combine our extensive industry experience with our innovative, vendor-neutral solutions to help you build and operate plants and assets in a reliable, safe and cost-effective manner.

Copyright 2010 Accenture All rights reserved. Accenture, its logo, and High Performance Delivered are trademarks of Accenture.

About Accenture
Accenture is a global management consulting, technology services and outsourcing company, with more than 190,000 people serving clients in more than 120 countries. Combining unparalleled experience, comprehensive capabilities across all industries and business functions, and extensive research on the worlds most successful companies, Accenture collaborates with clients to help them become high-performance businesses and governments. The company generated net revenues of US$21.58 billion for the fiscal year ended Aug. 31, 2009. Its home page is www.accenture.com.

ACC10-0612 / 11-1589