Præsentation fra PCTY 2012 - kundecase

1. Metsä Tissue
Maintenance Improvement Project (MIP)
CMMS project
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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+ needed
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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
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MIA 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!
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5. Metsä Tissue
Maintenance Improvement Project (MIP)
Timetable
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6. Timing of the CMMS project
MT CMMS (maintenance)
Inter
CMMS
Germany face
Germany
SAP Inter
Pre-plan
CMMS
MT CMMS CMMS CMMS
Nordics CMMS Template Sweden Mänttä
face
SAP
Inter
CMMS
Slovakia 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!
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7. MT MIP
Metsä Tissue
Maintenance Improvement Project
CMMS evaluation
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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)
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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 +++ ++ +
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10. Comparison tables of the CMMS systems
Item IBM, Maximo Competitor I Competitor II
5 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 +
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11. MT MIP
Metsä Tissue
Maintenance Improvement Project
Process improvements
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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 flow
By operators and maintainers By maintenance planners
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13. Hierarchical Structure in paper production and converting
…Site..
PM X
Approach …etc
Pumps, Rolls, etc Lowest
Hierarchy Level
Equipment
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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 PENETRATION
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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 MODIFICATION
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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 Maintenance
Improvements x x - Improvements
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17. Workorder criticality assessment by the CMMS
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18. Reporting / KPI Cockpit 4
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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 Nordic
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20. Graphical Navigation to Assets and Locations
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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 device
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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.
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23. Thank you for your attention!
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