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 •Tolko
•International Paper •Borregaard
•Hewlett Packard •Domtar
•Georgia Pacific •Eurocan
•Panama Canal Comission •Alcoa
•Rohm and Haas •Buckeye
•PanAsia Paper •Stora Enso
•Quatar Gas Company •Timken
•Kaiser Aluminum •ABB
•Weyerhaeuser •Riverwood
•Mead Paper •Northwood
•Assi Domän •Norke Skog
•Hercules Chemicals •Willamette
•Procter and Gamble •Sappi
•Kimberly Clarke •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 Maintenance and

Responsible for Engineering Responsible for
Process Reliability Equipment Reliability

Measure Reliability?

Measure plant bottlenecks

KEY PROCESS Defining Equipment Reliability

Current Best Practices (CBP)

Leadership Root Cause Planning Skills Preventive Stores Technical Engineering Facilities,
& Problem & Development Maintenance Management Database Interface with Tools, &
Organization Elimination Scheduling Maintenance Workshops

Work Request Maintenance Method Selection

SUB PROCESSES Prioritization Cleanliness
Backlog Lubrication
Planning Alignment
Scheduling Balancing
Execution Operating Procedures
Recording Filtration
CMMS Tool Condition Monitoring

Example 1. A few sample “Lubrication Example 2: A few example “Planning

ELEMENTS 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.
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 Chart

– Shift Maintenance w/ Supervision

– Day Crews
– PM Group
 MAINTENANCE &
ENGINEERING DEPT

M&E
Manager

Mech Maint E/I Planning Engineering Storeroom

Supt Supt Supt Dept

PMP Group Mech Maint E/I Mech & E/I

(2) Supvs (6) Supvs (5) Planners (7)
 SMURFIT-STONE CONTAINER CORP
MAINTENANCE & ENGINEERING DEPT

M&E
Manager

Mech Maint E/I Planning O/S & Shift Engineering Storeroom

Supt Supt Supt Supt Dept

Mech Maint Reliability E/I Mech & E/I Shift

Supvs (5) Group Supvs (3) Planners (5) Supvs (4)
– 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
Shutdown PMs
Training & Continuous
Improvement
Detailed Cleaning

Pump Shop
Mechanical Infrared
Inspections

Vibration Analysis Motor Circuit

Fernandina Beach Evaluator (MCE)
Reliability Group Test

Installation Standards
Motor Management
Mechanical Inspection
Routes

Electrical Infrared
Inspections Oil Analysis /
FMIO Lubrication Program
Bearing Life
Management/
Improvement
Root Cause
 Reliability Group Organization

Maintenance Superintendents

Reliability Group Leader

E&I PM Supv. Mech. PM Supv. Vibration Analyst Planner/Analyst

E&I Technicians PM Mechanics Vibration Technicians Pump Shop Mechanics

Lubrication Mechanics
 Results Oriented Maintenance
Productivity Improvement Cycle

PREVENT

• BACKLOG MANAGEMENT
• PRIORITIZE

TECHNICAL DATABASE PLAN IDENTIFY EARLY

SCHEDULE

INFORMATION

UNPLANNED WORK
ANALYZE &
CONTINUOUS
EVALUATION ACTION DO BREAK IN
JOBS
IMPROVEMENT

Circle of
DESPAIR
RECORD
Preventive Maintenance / Essential Care and
Condition Monitoring ( PM/ECCM )
PM/
PM/ECCM
ECCM

Essential
EssentialCare
Care FTM
FTM Condition
ConditionMonitoring
Monitoring
Lubrication

Alignment
Objective
Objective Subjective
Subjective
Balancing

Detailed Cleaning Vibration analysis Look

Operating practices IR Camera Listen

Installation practices Oil Analysis Feel

NDT Smell
Filtration
Pressure Checks
Adjustments
Stroboscope
Spike Energy
 Preventing Failures-
Electric 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 Look OK

50

0 0.15
0.04
0.01

0.1

1
0.06

0.09
0.05

0.25
0.5
0

0.08
0.03

0.07
0.02

0.2

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
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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 Clayton Smith
IDCON. INC. Smurfit Stone Corporation
7200 Falls of Neuse Rd, Suite 200. N. 8th Street.
Raleigh, NC, 27615 PO Box 2000
Phone +1 919 847 8764 Fernandina Beach, FL, 32035
Fax: +1 919 847 8647 Phone 904-277-5700
T_idhammar@idcon.com Fax: 904-277-5754
Lcsmith@smurfit.com
gmunn@smurfit.com