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Valmet Mill Maintenance Outsourcing – Best Maintenance Practices in Pulp and Paper Mill to Improve Profitability Vijay RathiVijay Rathi.

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Presentation on theme: "Valmet Mill Maintenance Outsourcing – Best Maintenance Practices in Pulp and Paper Mill to Improve Profitability Vijay RathiVijay Rathi."— Presentation transcript:

1 Valmet Mill Maintenance Outsourcing – Best Maintenance Practices in Pulp and Paper Mill to Improve Profitability Vijay RathiVijay Rathi

2 2 Rising raw material and energy costs Challenging global economic conditions Skills shortages Global industrial competition Increasing environmental and safety requirements Today’s challenges in Paper Making

3 © Valmet Paper mill operational cost distribution Variable costs dominate Commission0.0% Transportation0.0% Variable costs Pulps43.2% Chemicals11.6% Energy26.0% Water9.9% Other variable costs0.8% Fixed costs Personnel4.3% Maintenance mat.2.7% Overhead1.4% Other fixed costs0.0% Total costs100.0% Cost breakdown 0.0% 43.2 % 11.6% 26.0% 9.9% 0.8% 4.3% 2.7% 1.4% 0.0%

4 Four steps to Maintenance management For lower maintenance costs 4 Maintenance effectiveness Performance management Downtime & quality costs Corrective maintenance Maintenance costs Preventive maintenance Predictive maintenance Unplanned repair costs Planned maintenance costs

5 Maintenance efficiency Performance management compared to traditional concept 5 Years Maintenance Hours / ton Valmet Mill Service performance management concept Traditional maintenance concept Higher costs More corrective maintenance Lower technical availability Long-term cost optimization Fewer failures and repairs Highest efficiency and quality 3 July, 2014© Valmet | Author / Title

6 Valmet agreement services that help you to improve productivity AvailabilityEfficiencyRisk control Maximize availability while optimizing costs Intelligent maintenance Operational excellence Warehouse inventory Optimize operations to reach set targets Production Raw materials Energy Resources Control risks that would have an adverse effect on a plant and/or business Asset value Safety Environment Competence

7 7 Maintenance agreement − A systematic way to improve efficiency Agreement is a systematic approach to reach the set targets Cooperation starts with a thorough auditing phase, during which the development potential is studied and a development plan is prepared

8 Operational excellence through Agreement Management Energy opportunities Energy efficiency solutions to help minimize energy consumption Material opportunities Technologies to reduce the use of fiber and chemicals, minimize waste and lengthen the lifetime of machinery All these provide solutions to improve customer profitability Water opportunities Water management solutions for decreased fresh water consumption and increased reuse of process waters with less effluent and lower costs Working environment opportunities Solutions for a safe and healthy workplace and improved usability to help increase productivity 8 Emissions opportunities Solutions to help comply with legislation and achieve sustainability targets Mill Improvements

9 Mill maintenance outsourcing - Cooperation concept 9 Customer Valmet Mill Service No in-house maintenance personnel Production personnel perform contractually agreed preventive maintenance tasks Low and sustainable maintenance cost level Focus on process upkeep and efficiency Full maintenance responsibility Preventive maintenance Daily maintenance and shutdowns Spare parts management Valmet Roll maintenance Specialist knowledge and services Process development support Development focus Personnel skills and working methods Preventive maintenance and equipment lifecycle Effective use of information systems (CMMS) Other suppliers Supplier network management Cost-effective long-term cooperation One contractCommon targets 3 July, 2014© Valmet | Author / Title

10 Results through a unique combination of know- how Valmet’s combination of machinery, automation, process and maintenance know-how results in: 10 Flexibility and experience to offer customized service The right maintenance decisions to optimize maintenance costs Highest efficiency of operations based on process know- how 3 July, 2014© Valmet | Author / Title

11 Maintenance and production efficiently integrated 11 Typical way Cleaning facilities Engineering Material mgmnt Purchasing Maintenance Production Logistics Purchasing Valmet way Cleaning facilities Engineering Material mgmnt Purchasing Maintenance Production Logistics Purchasing Operate and maintain team 3 July, 2014© Valmet | Author / Title

12 Full maintenance concept - Clear process creates results 3 July, 2014© Valmet | Author / Title12 Maintenance audit Takeover and Change program Target operations Separate business operations

13 Professional maintenance audit - Content supports the future actions  We need to analyze –Maintenance practices –Production efficiency –Maintenance costs  We will propose –Realistic targets –Action plan 3 July, 2014© Valmet | Author / Title13

14 Practical Cases Approach Developing existing maintenance operations 14 Define savings & improvement Potential Maintenance Audit Pre study Audit Analyses of data Benchmarking Summary of conclusions Recommendations Presentation to mill management Define savings & improvement Potential Maintenance Audit Pre study Audit Analyses of data Benchmarking Summary of conclusions Recommendations Presentation to mill management Scope of co-operation Proposal Content and scope Targets KPI’s Safety Maintenance strategy Maintenance resources Trade union issues Scope of co-operation Proposal Content and scope Targets KPI’s Safety Maintenance strategy Maintenance resources Trade union issues Agreement Kick-off Teams establishment Project manager Action plan Communication to organizations Change program Agreement Kick-off Teams establishment Project manager Action plan Communication to organizations Change program New way to operate Implementation Maintenance management development (CMMS) Competence analyzes Training Motivation program New working methods Efficiency measurement RCM based analysis OEE development program New way to operate Implementation Maintenance management development (CMMS) Competence analyzes Training Motivation program New working methods Efficiency measurement RCM based analysis OEE development program Stabilizing operations Continuous improvement Evaluation of new way of operations Process development Quality support Safety development Network development Analysis of results New annual targets Partnership Stabilizing operations Continuous improvement Evaluation of new way of operations Process development Quality support Safety development Network development Analysis of results New annual targets Partnership Phase I Audit & analyze 1 m Phase II Tailor made scope and co-operation model 6-12 m Phase IV Development Phase III Implementation 12 m 3 July, 2014© Valmet | Author / Title

15 Maintain Improve Optimize Availability Efficiency Performance Keep the existing machinery up and running Valmet maintenance procedures Follow-up and monitoring Technology updates for improved efficiency Predictable costs Best Practices Keep the existing machinery up and running Valmet maintenance procedures Follow-up and monitoring Guaranteed results with minimum life cycle cost Valmet know how at the mill Risk sharing Technology updates for improved efficiency Predictable costs Best Practices Keep the existing machinery up and running Valmet maintenance procedures Follow-up and monitoring Step by step execution plan Mill Improvements

16 Paper machine profitability potential Values from an implemented project ( EXP.150 KT/Y) Savings per year EUR 1.2 million in total Savings per year EUR 1.2 million in total More production by EUR 2.1 million More production by EUR 2.1 million Fibre k€ Fibre k€ Drying k€ Drying k€ MD broke k€ MD broke k€ CD broke - 95 k€ CD broke - 95 k€ Maximise the production + 1,200 k€ Maximise the production + 1,200 k€ Broke => Prima k€ Broke => Prima k€ Maintenence costs k€ Mill Improvements

17 On-site analyses and measurements 360°Rolls Agreement How Valmet see the rolls enviorment in a Mill 17 Spare parts Showers LogisticsPress felts Dryer and forming fabrics Doctoring Uhle boxes Roll environment Roll maintenance Roll covers New rolls Shoe press belts Process conditions

18 Valmet Mill Service Amcor Packaging Pty Ltd, Botany, Australia  Greenfield 345 kton/year containerboard mill  Agreement started on July 12, 2011  Multi-year agreement including maintenance establishment, mill maintenance and management of improvement  Areas of responsibility –Mechanical, electrical and automation maintenance –Roll maintenance –Management of civil works –Planning, management and implementation of improvement projects 18

19 Liner/Fluting PM 7 Production capacity 470,000 t/year Grammage 75 – 145 g/m² Design speed 1,800 m/min Wire width 8,600 mm Machine data Performance agreement Case Mondi Swiecie PM 7, Poland  Agreement period started: 2011  Agreement period: Active  Targets –Improve time efficiency –Reduce specific energy consumption  Results –Time effiiciency has improved by about 7.5% since the agreement started –Energy consumption has decreased by about 1% during Results through cooperation

20 Coated fine paper, PM 4 Production capacity 210,000 t/year Grammage 65 – 90 g/m² Design speed 1,300 m/min Wire width 6,300 mm Machine data Performance agreement Case Sappi Kangas, Finland  Agreement period:  Scope –Project management –Steering group –Working groups for focused development areas –Common database –Remote services for specific areas –Special maintenance packages –Maintenance development and support  Results –Percentage of unplanned shutdowns due to maintenance reasons dropped continuously from 2.4% to 0.5% in 2004 –The customer reduced the maintenance personnel by 50% during the agreement period 20 M-real image bank Results through cooperation

21 Focus on Machine Performance and Productivity  “Maintenance costs lowered in Greåker 20% and in Säffle 25%.”  “The mill’s daily production increased in Greåker 30% and in Säffle 25%.”  “Energy usage lowered with 40% in Greåker and 20% in Säffle.” Nordic Paper Greåker & Säffle 21 Case Öysten Vedahl Mill Manager for Nordic Paper Greåker ( 2001 – 2010) Säffle (2005 – 2010) Key results from co-operation with Valmet Nordic Paper Greåker and Säffle 3 July, 2014© Valmet | Author / Title

22 Results and Discussion UPM, Plattling, Germany 22 MMS set up activities on schedule and recruited a very competent maintenance team.”  - Caius Murtola, General Manager - MMS set up activities on schedule and recruited a very competent maintenance team.”  - Caius Murtola, General Manager - ”We could not have set up the maintenance better ourselves.” - Mika Kämpe, Operations Manager - “Maintenance is a service function for the first time and not the main topic in the operations. I can concentrate on paper making.” - Olli Ylä-Jarkko, Production Manager PM July, 2014© Valmet | Author / Title

23 Summary 23 Skilled personnel Standard operating procedures Operator maintenance Maintenance systems Preventive maintenance and shutdowns Task force programs Sourcing Key performance indicators Complete maintenance operations 3 July, 2014© Valmet | Author / Title

24

25 Benchmarking (Example 150KT/Y WFU) 3 July, 2014© Valmet | Author / Title25

26 Benchmarking (Example 150KT/Y WFU) 3 July, 2014© Valmet | Author / Title26

27 Benchmarking (Example 150KT/Y WFU) 3 July, 2014© Valmet | Author / Title27


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