PCTY 2012, Kundecase - Metsä Tissue  Maintenance Improvement Project (MIP)
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PCTY 2012, Kundecase - Metsä Tissue Maintenance Improvement Project (MIP)

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Præsentation fra PCTY 2012 - kundecase

Præsentation fra PCTY 2012 - kundecase

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PCTY 2012, Kundecase - Metsä Tissue Maintenance Improvement Project (MIP) Presentation Transcript

  • 1. Metsä Tissue Maintenance Improvement Project (MIP) CMMS project1 22.05.12Presentation name
  • 2. The maintenance processes • The maintenance handbook is translated into Swedish, Slovakian and German language • Action plans are set up for nearly all mills: – Mariestad & Småland – Stotzheim, Kreuzau & Raubach – Krapkowice & partly Zilina – Mänttä under development • The experience all over shows that people like to have a clear description of their working processes • Updates in the area of procurement according One+ needed2 22.05.12Presentation name
  • 3. Original MT MAP of maintenance systems 1. Mattek system in Mänttä MS-DOS based from 1 late 80’s 2. 2 IBM Maximo 8 MS-DOS based system from ’97 3. API PRO 6 From year 2005 3 5 4 4.& 5. 7 Home made Excel solutions 6. Home made Access solutions 7. SAP for spare part warehousing 8. No maintenance system 3 22.05.12 Presentation nameMIA 2.10.2009
  • 4. Cross process and cross function improvements Warehouse Mgmt Information Structure 1 Common WH Management (Tools and processes for spare parts) System Integration Higher business continuity Integration of several systems, 7 3 due to modern system with less interfaces, monitoring sufficient knowhow available (interfacing of one CMMS Network worldwide to SAP) to grow ! Organization Master Data 6 Harmonized roles and activities 4 Data actuality and consistency through all regions Note: Easy to connect more production facilities later!4 22.05.12Presentation name
  • 5. Metsä Tissue Maintenance Improvement Project (MIP) Timetable5 22.05.12Presentation name
  • 6. Timing of the CMMS project MT CMMS (maintenance) Inter CMMSGermany face Germany SAP Inter Pre-plan CMMS MT CMMS CMMS CMMSNordics CMMS Template Sweden Mänttä face SAP Inter CMMSSlovakia face 2..3 licenses for Zilina SAP each mill to start CMMS Inter Poland face with pre-works after Poland SAP pilot 2009 2010 2011 2012 2013 • Independent from One+ project! • Separate Template phase to set up the system, as joint project with all MT regions • Sweden first as „stand alone system“ (as today) • Following roll outs: WE-, NEE-, CEE-region • Implementing 2..3 licenses in all mills after pilot phase in Sweden, to enable mills to start with preparations! 6 22.05.12 Presentation name
  • 7. MT MIP Metsä Tissue Maintenance Improvement Project CMMS evaluation7 22.05.12Presentation name
  • 8. Start of the CMMS project • We created beginning 2009 in an international working group a description of requirements based on our identified best practices coming from the maintenance handbook. • This description were send out in an RFQ to 3 vendors – Competitor I (SAP-solution) – Competitor II (API PRO-solution) – IBM (MAXIMO-solution)8 22.05.12Presentation name
  • 9. Comparison tables of the CMMS systems Item IBM, Maximo Competitor I Competitor II Long term supplier reliability ++ +++ + Operators connected to work ++ -- +++1 flow process Provide all needed + 0 +2 maintenance functionalities Purchase module + ++ + functionality Interfaces to ERP ++ +++ +3 Interfaces to machine PLC’s ++ --- ++ Resources planning tool +++ + +++4 employees, spare parts… Reporting capabilities +++ + ++ Budgeting tool on position, +++ ++ +++ equipment, work order level Web based system +++ ++ +9 22.05.12Presentation name
  • 10. Comparison tables of the CMMS systems Item IBM, Maximo Competitor I Competitor II5 Workflow process +++ -- ++6 Planning modul +++ - + Global data +++ +++ +++ sourcing Training +++ +++ + capabilities Project execution +++ ++ + References ++ +++ 0 Licenses - 0 +++ The licenses are limited The licenses are not limited Change +++ ++ 0 management support Price - + +++ Total ++ 0 + 10 22.05.12 Presentation name
  • 11. MT MIP Metsä Tissue Maintenance Improvement Project Process improvements11 22.05.12Presentation name
  • 12. Maintenance workflow process The following high level workflow must be implemented in each plant: History Close-out By production and maintenance Execution Scheduling Planning Priority Approval Work Request Emergency flowBy operators and maintainers By maintenance planners 12 22.05.12 Presentation name
  • 13. Hierarchical Structure in paper production and converting …Site.. PM X Approach …etc Pumps, Rolls, etc Lowest Hierarchy Level Equipment13 22.05.12Presentation name
  • 14. Failure codes Code Description ADJ WRONG ADJUSTMENT ANN ABNORMAL NOISE BLD BLOCKED ; JAMMED ; CLOGGED BRK BROKEN ; DAMAGED ; CRACKED MATERIAL CON CONDENSATION ; HUMIDITY COR CORRODED DCC DEFECTIVE ELECTRICAL / ELECTRONIC COMPONENT DCN DEFECTIVE ELECTRICAL / ELECTRONIC CONNECTION DCT DEFECTIVE ELECTRICAL / ELECTRONIC CIRCUIT DRT DIRTY ; DUSTY EMT EMPTY ; DISCHARGED FIX LOOSE FIXATION / MECHANICAL CONNECTION LEK LEAKING LUB INSUFFICIANT LUBRICATION NFI NO VISIBLE FAILURE INDICATION OVH OVERHEATED OR BURNED SHP OUT OF SHAPE; DISTORED ; BEND SMF SOFTWARE MALFUNCTION TRP TRIPPED CIRCUIT BREAKER / FUSE WAT WEAR AND TEAR WPT WATER PENETRATION14 22.05.12Presentation name
  • 15. Failure codes Code Description ADD ADDED ; REFILLED ; CHARGED ADJ ADJUSTED ; RESTORED ANC ACTION NOT CODED ; EXPLAIN CHK CHECKED ; INVESTIGATED ; TESTED CLE CLEANED FAS FASTENED ; FIXED ; GLUED ; CONNECTED GRD GROUND LUB LUBRICATED ; GREASED ; OILED MCH MACHINED (TURNING; MILLING; CUTTING OR SHAPING) PAI PAINTED RES RESETTED (SOFTWARE; FUSE; SYSTEM) RPF RE – PROFILED (TRAINS, WHEELS, CYLINDERS); Balancing & alignment RPC REPLACED – CONSUMABLE PARTS (LAMPS; BULBS) RPL REPLACED – SPARE PARTS SEA SEALED SRI SOFTWARE RE – INSTALLED WEL WELDED NFD NO FAILURE DETECTED NSD NO STATIC FAILURE DETECTED (DYNAMIC TEST REQUIRED IF FAILURE OCCURS AGAIN SOON) FKM FAILURE KNOWN – AWAITING MODIFICATION15 22.05.12Presentation name
  • 16. Workorder criticality assessment by the CMMS 2 5 Risk to production Tasks depend on Depend on law Sheduled predictive Sheduled preventive Depend on law Daily maintenance Tasks depend an Risk to Safety Risk to Environment (Tasks depend on projects and small immediatly maintenance maintenance sheduled task CIP fault reports) investments A 1 2 7 8 13 14 16 18 23 24 B 3 4 9 10 15 17 19 21 25 26 C 6 5 11 12 NA NA 20 22 27 28 Planned on regular Planned without Planned on yearly Priority Immediately maintenance shut Work Order Type(s) possible plant breakdown maintenance stop down Emergency x -Emergency (fault report) - Planned Corrective Maintenance - Preventive Maintenance Planned x x - Predictive Maintenance - Inspections - Planned Corrective Maintenance Routine x x - Preventive Maintenance - Predictive MaintenanceImprovements x x - Improvements16 22.05.12Presentation name
  • 17. Workorder criticality assessment by the CMMS17 22.05.12Presentation name
  • 18. Reporting / KPI Cockpit 418 22.05.12Presentation name
  • 19. Drag and drop scheduling of shut downs 6 MAXIMO scheduler Automatic rescheduling to critical line Different colours depending on status or priority Arrows shows the The resulting resource load is dependencies Showed in different colours between tasks per skil. When moving task or Work orders the load is dynamically showed 15 © 2007 IBM Software Group Nordic19 22.05.12Presentation name
  • 20. Graphical Navigation to Assets and Locations20 22.05.12Presentation name
  • 21. Mobile Solution in the Store Room • Handheld computer with barcode scanner • Syncstation and/or wireless connectivity • On-the-fly physical count • Materials reserved for workorder is like a pick list in the device21 22.05.12Presentation name
  • 22. Workflow for Purchase approval • Three-tier approval level solution, based on monetary limits • <€500 can be approved by storeroom manager, larger amounts must be approved • Process includes a Purchase by either maintenance, mill or Requisition (PR) that can be regional manager created manually or by automatic reorder process (store room balances have reached order point). Approved PR is converted to a PO and handled by Metsä’s sourcing people.22 22.05.12Presentation name
  • 23. Thank you for your attention!23 22.05.12Presentation name