Building a Cost Effective Reliability Process

Presented by: Tor Idhammar, Consultant, IDCON, INC. George Munn, Maintenance Supervisor, Smurfit Stone Corporation

 Present Examples of Current Best Practices for Reliability and Maintenance Revitalization of the Reliability Process at Smurfit Stone, Fernandina Beach Mill

Raleigh, N.C

Reliability and Maintenance management Consultants

Assessments Planning and Scheduling Preventive Maintenance Root Cause Problem Elimination Store Improvements Benchmarking Trips to Europe Annual Reliability Conference (Atlanta Nov 5-8) www.paperindustrymaintenance.com Books

Recent Projects

Smurfit-Stone International Paper Hewlett Packard Georgia Pacific Panama Canal Comission Rohm and Haas PanAsia Paper Quatar Gas Company Kaiser Aluminum Weyerhaeuser Mead Paper Assi Domn Hercules Chemicals Procter and Gamble Kimberly Clarke

Tolko Borregaard Domtar Eurocan Alcoa Buckeye Stora Enso Timken ABB Riverwood Northwood Norke Skog Willamette Sappi Atlantic Packaging

Smurfit-Stone Overview

Headquarters - Chicago, IL Industry - Containers & Packaging 40,000 Employees 8.1 Billion Dollars Sales

Smurfit-Stone Container Corp. Fernandina Beach, Florida

Fernandina Beach Mill Information

2,850 Tons Per Day Three Linerboard Machines Two - 240 trim, Conventional Fourdriniers One - 160 trim, Twin Wire Fourdrinier Two-Ply Brown Linerboard, 26# - 69# ISO 9002 Certification Work Force - 615 Maintenance - 196

RELIABILITY?
Production Reliability

Operations Responsible for

Maintenance and Engineering Responsible for

Process Reliability

Equipment Reliability

Measure Reliability?

Measure plant bottlenecks

KEY PROCESS

Defining Equipment Reliability Current Best Practices (CBP)

Leadership & Organization

Root Cause Problem Elimination

Planning & Scheduling

Skills Development

Preventive Maintenance

Stores Management

Technical Database

Engineering Interface with Maintenance

Facilities, Tools, & Workshops

SUB PROCESSES

Work Request Prioritization Backlog Planning Scheduling Execution Recording CMMS Tool

Maintenance Method Selection Cleanliness Lubrication Alignment Balancing Operating Procedures Filtration Condition Monitoring

ELEMENTS

Example 1. A few sample Lubrication Elements 26. Lubricants are stored properly in clean, organized storage areas. 27. Filtration is used to maintain lubricant cleanliness. 28. Ferro graphic analysis is used to identify oil contaminants and contamination levels.

Example 2: A few example Planning elements 32. Standard job plans are used for all repetitive and critical jobs 33. Jobs are always planned before they are scheduled 34. Operations support the planning process

Process Implementation

1. Management provide Charter to improvement team 2. Team develops mission statement 3. Team develop detailed plan 4. Team revise plan continuously 5. Processes are established
Process = Documentation + Execution + Tracking/ KPI

 Paradigm Shift Overall Machine Efficiency Maintenance Cost/Ton Number of Occurrences

 Prior Organization

Chart

Vision & Implementation Internal Restructuring

Shift Maintenance w/ Supervision Day Crews PM Group
Chart

MAINTENANCE & ENGINEERING DEPT

M&E Manager
Mech Maint Supt
PMP Group (2) Mech Maint Supvs (6)

E/I Supt
E/I Supvs (5)

Planning Supt
Mech & E/I Planners (7)

Engineering Dept

Storeroom

SMURFIT-STONE CONTAINER CORP MAINTENANCE & ENGINEERING DEPT

M&E Manager
Mech Maint Supt
Mech Maint Supvs (5) Reliability Group

E/I Supt
E/I Supvs (3)

Planning Supt
Mech & E/I Planners (5)

O/S & Shift Supt

Shift Supvs (4)

Engineering Dept

Storeroom

 Benchmarking Expedition ROM Seminar Gap Analysis

Develop a reliability based maintenance group based on preventive and predictive maintenance principles with world class results as a target.

 The program to be sold to:

Top Management Operations & Maintenance Supervisors Hourly Personnel

 Fewer failures Find failures earlier Improved equipment reliability Improvements in housekeeping & safety

 Preventive Maintenance (Essential Care) Predictive Maintenance (Condition Monitoring) Root Cause Failure Analysis Training

Tools & Systems Utilized

CMMS - INDUS Passport TeReMa - Route Based Software Mobil Lubrication Management (LMS) Vibration Analysis Infrared Thermography Motor Circuit Evaluator

Coupling Guards Training & Continuous Improvement Shutdown PMs Detailed Cleaning

Pump Shop Mechanical Infrared Inspections Vibration Analysis

Fernandina Beach Reliability Group

Motor Circuit Evaluator (MCE) Test Installation Standards

Motor Management Mechanical Inspection Routes Electrical Infrared Inspections

FMIO Bearing Life Management/ Improvement Root Cause

Oil Analysis / Lubrication Program

Reliability Group Organization

Maintenance Superintendents

Reliability Group Leader

E&I PM Supv.

Mech. PM Supv.

Vibration Analyst

Planner/Analyst

E&I Technicians

PM Mechanics Lubrication Mechanics

Vibration Technicians

Pump Shop Mechanics

Results Oriented Maintenance Productivity Improvement Cycle

PREVENT

BACKLOG MANAGEMENT PRIORITIZE

TECHNICAL DATABASE

PLAN SCHEDULE
INFORMATION

IDENTIFY EARLY

ANALYZE &
CONTINUOUS IMPROVEMENT EVALUATION ACTION

UNPLANNED WORK

DO

BREAK IN JOBS

Circle of DESPAIR

RECORD

Preventive Maintenance / Essential Care and Condition Monitoring ( PM/ECCM )

PM/ PM/ECCM ECCM

Essential EssentialCare Care

Lubrication Alignment Balancing Detailed Cleaning Operating practices Installation practices Filtration Adjustments

FTM FTM

Condition ConditionMonitoring Monitoring

Objective Objective
Vibration analysis IR Camera Oil Analysis NDT Pressure Checks Stroboscope Spike Energy

Subjective Subjective
Look Listen Feel Smell

Preventing FailuresElectric Motor Life Example

Rule:

An 18 F Increase In Temperature Reduces Motor Life By 50%

Preventing Failures Effects of water in oil in bearings

250 200
% remaining life

150 Milky 100 50 0 Look OK

0.04

0.15

0.01

0.1

0.06

0.09

0.05

0.25

0.08

0.03

0.02

0.07

0.5

0.2

% water
Based on 100% life at 100 ppm water in oil

Facts!

People make the difference! Lubrication is the cornerstone! As vibration levels decrease equipment life will increase!

Essential Care

Lubrication Routes & Standards Detailed Cleaning

Lubrication Program Mission Statement

To provide a lubrication program whereby the correct uncontaminated amount of lubricant is delivered to equipment at the proper frequency while minimizing leakage and consumption.

Lubrication Improvements

Institute New Practices Baseline Cleanliness/Better Filtration Centralize Lubricators

Lubrication Improvements

Software to Manage Lubrication Routes Focus on Reducing Hydraulic Leaks Close Working Relationship w/ Supplier Lube Point Labels

Condition Monitoring Inspection Routes Vibration Analysis Oil Analysis Infrared Thermography

CLICK ON PM OBJECTS

F
200 190 S2 180 170 160 150 S1 140 130 120 110 100 90

F
200 S2 190 180 170 160 150 S1 140 130 120 110 100 90

F
600 550 500 450 S2 S1 400 350 300 250 200 150 100 50

F
200 190 180 170 160 150 140 130 120 110 100 90 80

F
240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 90 80 70

F
200 190 180 170 160 150 140 130 120 110 100 90 80

Special Projects

Labeling Guard Modifications Gauges

E&I PM Responsibilities

Motor Management Motor Testing Infrared Inspections

Key Performance Indicators

Cost of Manufacturing/Maintenance Cost Unplanned Downtime Planned & Scheduled Work Break-In Work Repeat Failures Route Compliance Work Orders Generated From Routes Work Orders Completed From Routes

Project Milestones

Started Planning - 11/99 Implementation - 3/00 Inspection Routes - 6/00 Complete Implementation - 12/01

Future

Implement Lubrication & Oil Analysis Program Changes Synergies Within Group, Consolidation of Functions (Data Collection/Inspections/etc.) Continuously Train & Improve

Challenges

Resources Communication Resistance to Change

It must be remembered that there is nothing more difficult to plan, more uncertain of success, nor more dangerous to manage than the creation of a new order of things. For the initiator has the enmity of all those who would profit by the preservation of the old institutions and merely lukewarm defenders in those who would gain by the new ones.

Niccolo Machiavelli -1513

Tor Idhammar IDCON. INC. 7200 Falls of Neuse Rd, Suite 200. Raleigh, NC, 27615 Phone +1 919 847 8764 Fax: +1 919 847 8647 [email protected]

Clayton Smith Smurfit Stone Corporation N. 8th Street. PO Box 2000 Fernandina Beach, FL, 32035 Phone 904-277-5700 Fax: 904-277-5754 [email protected] [email protected]