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Metsä Tissue Maintenance Improvement Project (MIP)

CMMS project

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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+ needed

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Original MT MAP of maintenance systems

MIA 2.10.2009

1

2

34

8

5

1.Mattek system in Mänttä MS-DOS based from late 80’s

2.IBM MaximoMS-DOS based system from ’97

3. API PROFrom year 2005

4.& 5.Home made Excel solutions

7

6

6.Home made Access solutions

7.SAP for spare part warehousing

8.No maintenance system

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Cross process and cross function improvements

7

6 4

1

3Network to grow !

Warehouse Mgmt

Master DataData actuality and consistency through all regions

Harmonized roles and activities

Organization

Common WH Management (Tools and processes for spare parts)

System Integration

Integration of several systems, less interfaces, monitoring(interfacing of one CMMS to SAP)

InformationStructure

Higher business continuity due to modern system with sufficient knowhow available worldwide

Note: Easy to connect more production facilities later!

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Metsä Tissue Maintenance Improvement Project (MIP)

Timetable

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Timing of the CMMS project

Inter

face

SAP

2009 20122010 2011

Slovakia

Poland

MT CMMS (maintenance)

Germany

Nordics

CMMS

Germany

CMMS

Mänttä

CMMS

Zilina

CMMS

Poland

Pre-plan

CM

MS

2013

Inter

face

SAPInter

face

SAPInter

face

SAP

CMMS

2..3 licenses for each mill to start with pre-works after pilot

MT CMMS

Template

• 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!

CMMS

Sweden

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MT MIPMetsä Tissue

Maintenance Improvement Project

CMMS evaluation

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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)

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Comparison tables of the CMMS systems

Item IBM, Maximo Competitor I Competitor II

Long term supplier reliability ++ +++ +

Operators connected to work flow process

++ - - +++

Provide all needed maintenance functionalities

+ 0 +

Purchase module functionality

+ ++ +

Interfaces to ERP ++ +++ +

Interfaces to machine PLC’s ++ - - - ++

Resources planning tool

employees, spare parts…

+++ + +++

Reporting capabilities +++ + ++

Budgeting tool on position, equipment, work order level

+++ ++ +++

Web based system +++ ++ +

1

4

3

2

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Comparison tables of the CMMS systems

Item IBM, Maximo Competitor I Competitor II

Workflow process +++ - - ++

Planning modul +++ - +

Global data sourcing

+++ +++ +++

Training capabilities

+++ +++ +

Project execution +++ ++ +

References ++ +++ 0

Licenses -The licenses are limited

0 +++The licenses are not limited

Change management support

+++ ++ 0

Price - + +++

Total ++ 0 +

5

6

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MT MIPMetsä Tissue

Maintenance Improvement Project

Process improvements

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Maintenance workflow process

The following high level workflow must be implemented in each plant:

WorkRequest

Approval

Priority

Planning

Scheduling

Execution

Close-out

History

WorkRequest

Approval

Priority

Planning

Scheduling

Execution

Close-out

History

Emergency flow

By operators and maintainers By maintenance planners

By production and maintenance

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Failure codesCode 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 PENETRATION

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Failure codesCode 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 MODIFICATION

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Workorder criticality assessment by the CMMS

Risk to Safety Risk to EnvironmentDepend on law

immediatly

Risk to production (Tasks depend on

fault reports)

Sheduled predictive maintenance

Sheduled preventive maintenance

Depend on law sheduled

Daily maintenance task

Tasks depend an CIP

Tasks depend on projects and small

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

Priority ImmediatelyPlanned without plant breakdown

Planned on regular maintenance shut

down

Planned on yearly maintenance stop

Emergency x

Planned x x

Routine x x

Improvements x x

Work Order Type(s) possible

-Emergency (fault report)

- Planned Corrective Maintenance- Preventive Maintenance- Predictive Maintenance- Inspections

- Planned Corrective Maintenance- Preventive Maintenance- Predictive Maintenance

- Improvements

2 5

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Workorder criticality assessment by the CMMS

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Reporting / KPI Cockpit 4

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Drag and drop scheduling of shut downs

15 © 2007 IBM Software Group Nordic

MAXIMO scheduler

Arrows shows the dependencies between tasks

The resulting resource load is Showed in different coloursper skil. When moving task or Work orders the load isdynamically showed

Different colours depending on status or priority

Automatic rescheduling to critical line

6

Graphical Navigation to Assets and Locations

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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 device

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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 by either maintenance, mill or regional manager

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• Process includes a Purchase Requisition (PR) that can be 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.

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Thank you for your attention!