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 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
Maintenance and
Engineering Responsible for
Equipment Reliability
Operations
Responsible for
Process Reliability
Measure Reliability?
Measure plant bottlenecks
Skills
Development
Technical
Database
Planning
&
Scheduling
Root Cause
Problem
Elimination
Preventive
Maintenance
Facilities,
Tools, &
Workshops
Engineering
Interface with
Maintenance
Stores
Management
Maintenance Method Selection
Cleanliness
Lubrication
Alignment
Balancing
Operating Procedures
Filtration
Condition Monitoring
Work Request
Prioritization
Backlog
Planning
Scheduling
Execution
Recording
CMMS 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 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
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 Maint
Supvs (6)
Mech Maint
Supt
E/I
Supvs (5)
E/I
Supt
Mech & E/I
Planners (7)
Planning
Supt
Engineering
Dept
Storeroom
M&E
Manager
SMURFIT-STONE CONTAINER CORP
MAINTENANCE & ENGINEERING DEPT
Mech Maint
Supvs (5)
Reliability
Group
Mech Maint
Supt
E/I
Supvs (3)
E/I
Supt
Mech & E/I
Planners (5)
Planning
Supt
Shift
Supvs (4)
O/S & Shift
Supt
Engineering
Dept
Storeroom
M&E
Manager
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 Beach
Reliability Group
Training & Continuous
Improvement
Pump Shop
Vibration Analysis
Motor Management
Electrical Infrared
Inspections
FMIO
Management/
Root Cause
Bearing Life
Improvement
Oil Analysis /
Lubrication Program
Mechanical Inspection
Routes
Motor Circuit
Evaluator (MCE)
Test
Mechanical Infrared
Inspections
Shutdown PMs
Coupling 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 Cycle
Productivity Improvement Cycle
DO
PREVENT
CONTINUOUS
IMPROVEMENT
ANALYZE &
RECORD
TECHNICAL DATABASE IDENTIFY EARLY
UNPLANNED WORK
BREAK IN
JOBS
BACKLOG MANAGEMENT
PRIORITIZE
PLAN
SCHEDULE
Circle of
DESPAIR
Preventive Maintenance / Essential Care and
Preventive Maintenance / Essential Care and
Condition Monitoring ( PM/ECCM )
Condition Monitoring ( PM/ECCM )
PM/ ECCM
PM/ ECCM
Essential Care
Essential Care
Condition Monitoring
Condition Monitoring
FTM
FTM
Objective
Objective
Subjective
Subjective
Vibration analysis
IR Camera
Oil Analysis
Lubrication
Alignment
Balancing
Detailed Cleaning
Operating practices
Installation practices
Filtration
Adjustments
NDT
Pressure Checks
Look
Listen
Feel
Smell
Stroboscope
Spike Energy
Rule:
An 18 F Increase
In Temperature
Reduces Motor Life
By 50%
Preventing Failures-
Electric Motor Life Example
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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
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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
T_idhammar@idcon.com
Clayton Smith
Smurfit Stone Corporation
N. 8
th
Street.
PO Box 2000
Fernandina Beach, FL, 32035
Phone 904-277-5700
Fax: 904-277-5754
Lcsmith@smurfit.com
gmunn@smurfit.com