The document discusses the importance of adapting maintenance and inspection strategies to the criticality of equipment to enhance competitiveness and reduce unplanned stops. It outlines common challenges in maintenance practices, opportunities for proactive activities, and a work process model for optimizing these efforts. Conclusions emphasize the necessity of organizational support, training for personnel, and a structured approach to implementing such systems over a typical 2-3 year period.

1. 1
Maintenance and inspection
adapted to equipment criticality
– essential for competitiveness
Jens Gunnars, Inspecta
Ola Jonsson, Holmen Iggesund
SPCI Convention 2013

2. Content
3
1. Expectations and problems for maintenance
2. Opportunities by implementation of maintenance & inspection
adapted to equipment criticality and condition
3. Work process model for optimization of proactive activities
4. Challenges in the execution of the different steps
5. Conclusions

3. Content
4
1. Expectations and problems for maintenance
2. Opportunities by implementation of maintenance & inspection
adapted to equipment criticality and condition
3. Work process model for optimization of proactive activities
4. Challenges in the execution of the different steps
5. Conclusions

4. Typical challenges and expectations on maintenance & inspection
5
• Reduce the number of failures and stops
• Provide fast repairs, of high quality
• Shorter and fewer planned stops
• Improve safety
• Efficient prioritization and use of personnel
• Keep the team motivated

5. Some common problems for proactive maintenance & inspection
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• Not having resources or desire for continuous improvement
‒ Sitting back satisfied with procedures and technology that were
up to date 15 years ago
• Lack of time for development of proactive maintenance work
‒ Urgent problems, or large rebuild projects , distracting focus to
the more long-term preventive maintenance work
• Reduction of personnel for cost savings and survival in downturns
‒ All resources required for the corrective work, no time for
preventive work
• Number of tasks overwhelming by time
‒ Due to new systems, new equipment and suppliers added
‒ Lack of time for re-evaluation of the plan for maintenance tasks

6. Content
7
1. Expectations and problems for maintenance
2. Opportunities by implementation of maintenance & inspection
adapted to equipment criticality and condition
3. Work process model for optimization of proactive activities
4. Challenges in the execution of the different steps
5. Conclusions

7. Opportunities by adapting maintenance to equipment criticality
8
• Planned, proactive maintenance & inspection
activities has the purpose to detect damage and
replace parts before they fail and cause
production stop.
• Analysis of the criticality of each equipment with
respect to their importance for
q production
q safety
can be used as a mean to obtain an efficient plan
for the proactive activities

8. • Proactive monitoring, inspection and prediction of the
condition of the equipment can be focused to objects of
high criticality.
• A common work process and concepts can be used for
all maintenance groups (Pulp and Paper), for the
planning of proactive maintenance, monitoring,
inspections and tests.
• This provides a structured process for the prioritization
of proactive work, with the overall aim to
‒ Reduce the number of failures and stops
‒ Focusing resources for early detection of damage
in high impact objects
Opportunities by adapting maintenance to equipment criticality
9

9. Content
10
1. Expectations and problems for maintenance
2. Opportunities by implementation of maintenance & inspection
adapted to equipment criticality and condition
3. Work process model for optimization of proactive activities
4. Challenges in the execution of the different steps
5. Conclusions

10. Requirements on a work process for optimization of
Preventive Maintenance & Inspection
• Systematic work method for going through the systems
and also for breakdown to components
• Practical work process
− Simplified and adapted to local needs
− Re-use of work per object types
− Involvement of the personnel for knowledge and commitment
• Using risk and reliability principles
• Use industry experience
− Failure modes, damage causes, statistics, good practices for diagnostics, ...
• Complementing preventive actions
− Monitoring, inspection and tests for condition diagnostics and prognostics
− Regular replacements
− Prepared repair work
• Efficient connection to maintenance system (from input data to work orders)

11. General work process model for optimization of proactive activities
– some important steps
12
Operating conditions,
functionality,
item data, history,
spare parts
Predictable
Yes No
Cost
efficient
FMEA
- Damage mechanisms & Causes
- Failure patterns, subcomponents
- Possible mitigation strategies
- Templates per object type
No
Yes
Feedback for
continuous
improvement
Scheduling
Run to failure
Evaluation of preventive
approaches
- Condition monitoring and prognosis
- Periodic inspection
- Periodic tests
- Residual life assessment
- Periodic replacement
Criticality Analysis
Monitor condition
/ performance

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Analysis of equipment criticality with respect to production
– Evaluation of equipment utilization (A, P, Q) and safety (S)
365 days
Planned outages
Unplanned stops
Used capacity
Quality yield
A
P
Q
• The utilization of a process plant may be measured using the concept
Overall Equipment Effectiveness, OEE = A x P x Q, where the indexes are
(A) Availability - percentage of scheduled time available for production (uptime)
(P) Performance - percentage use of the designed production speed/capacity
(Q) Quality - percentage of production with good quality
• In addition a performance index for safety and environment should be used (S)
• The criticality of each equipment with respect to the production and safety is
assessed by use of the indexes A, P, Q, S

13. 15
Condition monitoring and prognostics
Continuous or periodic diagnostics
Different types of methods for condition monitoring:
• Periodic walkdowns; general physical inspection of equipment
• Process parameters; reduced performance, cycles, limits
• Vibration monitoring; measurement and analysis, spectrum, balancing
• Non Destructive Evaluation; visual inspection, thermography, acoustics, ultrasonic,
radiography, magnetic, eddy current, replica, …
• Oil and particle analysis
• Analysis of corrosion environment
• Mechanical measurements; alignment, tolerances
• …
The condition result is used for prognostics based on:
- Physical models for the damage/failure evolution, or
- Data driven approaches/statistical relations

14. Content
16
1. Expectations and problems for maintenance
2. Opportunities by implementation of maintenance & inspection
adapted to equipment criticality and condition
3. Work process model for optimization of proactive activities
4. Challenges in the execution of the different steps
5. Conclusions

15. Summary of ongoing Iggesund project for development of PM
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§ Common project for all maintenance groups at the mill
§ Started with development of work concept
‒ Utilizing proven methods as much as possible
§ Criticality analysis
‒ Analysis of all systems in the mill is accomplished
§ Detailed work ongoing for critical equipment (red line)

16. Maintenance
work load
Maintenance work
Business as usual…
Unplanned stops
under control by
corrective
maintenance,
but resources could
be better used…
Implementation
of adapted PM.
Tough period.
Temporary peak
in work load.
Reduced numbers of
failures and unplanned
stops. Increased degree
of planning of PM work.
Increased focus to critical
equipment, decreased
focus to other.
Higher reliability by
reduced number of
failures and stops.
Decrease in
maintenance costs.
1 2 3 Time
Budget
Adaptation of Preventive Maintenance to the equipment criticality
– Temporary tough peak during implementation
Start of
development for
PM adaption

17. Challenges in the execution
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• Documentation and basic data
− Hugh work to secure complete electronic
documentation
• Functional descriptions for the equipment
− Descriptions of specific requirements for our process
− Connections to other parts of the process
• Compilation of historical data
− Good event classification is very valuable
− Reporting discipline will become evident
• Use of templates for different object types
− Provides large time savings

18. Challenges in the execution
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• Criticality analysis
− Use of own model based on OEE and HSE
− Classification is easy if background information is
complete
• Classification of subsystems and parts
− Efforts to identify the weakest links, in order to find
the right methods for condition assessment, or
rebuild
• Assessment of alternative preventive actions
− Cost-benefit assessment used
• Scheduling and instructions
− Packaging of task when PM planning is performed
for several objects
− Instructions so that no tasks are dependent on
individual persons

19. Content
21
1. Expectations and problems for maintenance
2. Opportunities by implementation of maintenance & inspection
adapted to equipment criticality and condition
3. Work process model for optimization of proactive activities
4. Challenges in the execution of the different steps
5. Conclusions

20. Conclusions
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• Implementation of adapted preventive maintenance & inspection in
relation to the equipment criticality and condition is important for
‒ focusing resources to high impact proactive activities
‒ reducing unplanned stops
• Some challenges to be aware of at implementation
‒ Support and patience from the top management is necessary.
It is typically a 2-3 years project. Basic education recommended.
‒ Important to establish well thought-out work systematics
‒ Training of personnel, also for acceptance of the methodology to
increasing the desire for change
‒ During the first implementation period the peak in work load is
substantial

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Thank you!
Questions?