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

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

Raleigh, N.C

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 Domän•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

Maintenance and Engineering Responsible forEquipment Reliability

OperationsResponsible for

Process Reliability

Measure Reliability?

Measure plant bottlenecks

SkillsDevelopment

TechnicalDatabase

Planning&

Scheduling

Root CauseProblem

EliminationPreventive

MaintenanceFacilities,Tools, &

Workshops

Engineering Interface with Maintenance

Stores Management

Maintenance Method SelectionCleanlinessLubricationAlignmentBalancingOperating ProceduresFiltrationCondition Monitoring

Work RequestPrioritizationBacklogPlanningSchedulingExecutionRecordingCMMS Tool

KEY PROCESS

SUB PROCESSES

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

Leadership &

Organization

Defining Equipment Reliability

Current Best Practices (CBP)

1. Management provide “Charter” to improvement team2. Team develops “mission statement” 3. Team develop detailed plan4. Team revise plan continuously5. Processes are established

• Process = Documentation + Execution + Tracking/ KPI

Process Implementation

• Paradigm Shift

• Overall Machine Efficiency

• Maintenance Cost/Ton

• Number of Occurrences

• Prior Organization Chart

• Vision & Implementation

• Internal Restructuring Chart

– Shift Maintenance w/ Supervision– Day Crews– PM Group

MAINTENANCE & ENGINEERING DEPT

PMP Group(2)

Mech MaintSupvs (6)

Mech MaintSupt

E/ISupvs (5)

E/ISupt

Mech & E/IPlanners (7)

PlanningSupt

EngineeringDept

Storeroom

M&EManager

SMURFIT-STONE CONTAINER CORPMAINTENANCE & ENGINEERING DEPT

Mech MaintSupvs (5)

ReliabilityGroup

Mech MaintSupt

E/ISupvs (3)

E/ISupt

Mech & E/IPlanners (5)

PlanningSupt

ShiftSupvs (4)

O/S & ShiftSupt

EngineeringDept

Storeroom

M&EManager

– 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

Fernandina BeachReliability Group

Training & ContinuousImprovement

Pump Shop

Vibration Analysis

Motor Management

Electrical Infrared Inspections FMIO

Management/Root Cause

Bearing LifeImprovement

Oil Analysis /Lubrication Program

Mechanical InspectionRoutes

Motor CircuitEvaluator (MCE)Test

Mechanical InfraredInspections

Shutdown PMsCoupling Guards

Detailed Cleaning

Installation Standards

Reliability Group Organization

E&I Technicians

E&I PM Supv.

PM Mechanics

Lubrication Mechanics

Mech. PM Supv.

Vibration Technicians

Vibration Analyst

Pump Shop Mechanics

Planner/Analyst

Reliability Group Leader

Maintenance Superintendents

EVALUATION

INFORMATION

ACTION

Results Oriented Maintenance Results Oriented Maintenance Productivity Improvement CycleProductivity Improvement Cycle

DO

PREVENT

CONTINUOUSIMPROVEMENT

ANALYZE &

RECORD

TECHNICAL DATABASE IDENTIFY EARLY

UNPLANNED WORK

BREAK INJOBS

• BACKLOG MANAGEMENT• PRIORITIZE

PLAN

SCHEDULE

Circle ofDESPAIR

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

PM/ ECCMPM/ ECCM

Essential CareEssential Care Condition MonitoringCondition MonitoringFTMFTM

ObjectiveObjective SubjectiveSubjective

Vibration analysis

IR Camera

Oil Analysis

Lubrication

Alignment

Balancing

Detailed Cleaning

Operating practices

Installation practices

Filtration

Adjustments

NDT

Pressure Checks

Look

ListenFeel

Smell

Stroboscope

Spike Energy

Rule:An 18 °F Increase

In TemperatureReduces Motor Life

By 50%

Preventing Failures-Electric Motor Life Example

0

50

100

150

200

2500

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09 0.1 0.15

0.2 0.25 0.5

1 2

% water

% re

mai

ning

life

MilkyLook OK

Based on 100% life at 100 ppm water in oil

Preventing Failures –Effects of water in oil in bearings

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

90

100

110

120

130

140

150

160

170

180

190

200

°F

S1

S2

90

100

110

120

130

140

150

160

170

180

190

200°F

S1

S2

50

100

150

200

250

300

350

400

450

500

550

600

°F

S1

S2

80

90

100

110

120

130

140

150

160

170

180

190

200°F

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

°F

80

90

100

110

120

130

140

150

160

170

180

190

200

°F

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 IdhammarIDCON. INC.7200 Falls of Neuse Rd, Suite 200.Raleigh, NC, 27615Phone +1 919 847 8764Fax: +1 919 847 8647T_idhammar@idcon.com

Clayton SmithSmurfit Stone CorporationN. 8th Street.PO Box 2000Fernandina Beach, FL, 32035Phone 904-277-5700Fax: 904-277-5754Lcsmith@smurfit.comgmunn@smurfit.com