Smurfit Westrock Boosts Maintenance Availability of Paper Machine

The original version of this interview was published in the NVDO, the Dutch Maintenance Organization's magazine: Vakblad Asset Management.

Insufficient Preventive Maintenance Setup

Dolf ter Schure, Maintenance Engineering Manager at SWP, explains the rationale behind the FMECA project. "In 2016, we converted paper machine 2 (PM2) from a newsprint machine into a cardboard machine and built a (mostly) new Recovered Fiber (RCF) facility. The RCF facility is in line with PM2 and supplies the raw material for it. PM2 produces two types of packaging paper from 100% recycled paper: fluting (corrugated) and testliner (smooth surface), which are used in corrugated cardboard. PM2 has a production capacity of 400,000 tons per year. During the startup phase, preventive maintenance was not prioritized as a contributor to effectiveness. The initial idea was to build preventive maintenance through RCAs, but that meant waiting for each failure to happen and then analyzing it to prevent future occurrences – not very efficient. In 2021, we began a phased FMECA project with MaxGrip to examine our machines' failure behavior, identify risks, and address these through maintenance plans and effective spare parts management." Based on the analysis of unplanned downtime, specific sections of the machine are designated for focus, with weekly sessions involving maintenance and production team members, a maintenance engineer, and a MaxGrip facilitator. Ter Schure notes, "This diversity of knowledge and experience, both technical and operational, has definitely paid off for our company."

Improving Together

SWP views the collaboration between departments as one of the most significant benefits of the FMECA project. Niels van Druten, Mechanical Technician with the maintenance team, shares his perspective: "In the past, I would look at the machine superficially if something went wrong, but now we all dig into it together. Documentation is faster and easier to read. We also share knowledge, and it quickly becomes clear that we need each other to improve." Mike Scheffer, First Operator of PM2 at the paper mill, agrees, saying, "As an operator without a technical background, these sessions have been very valuable for me. We examine machine components more closely, share information and knowledge, and this has a positive impact. Now, I'm able to handle minor issues myself, plan replacements, and assemble or disassemble parts as needed."

"Flat-Pack" Maintenance Kit

With thorough FMECA sessions and leveraging cross-functional collaboration, the paper mill team has laid the groundwork for more accurate, action-oriented maintenance plans, positively impacting planning and work preparation. The proactive maintenance approach not only addresses current problems but anticipates future challenges, allowing for efficient resource allocation and strategically planned maintenance activities. Ter Schure explains, "For preventive maintenance, less preparation is needed since much is already in place – drawings, spare parts, everything is connected. It's like having a prepared 'flat-pack' maintenance kit, which saves a lot of work."

Increased Technical Availability

Ter Schure closely tracks the outcomes of the FMECA project. "Doing the right maintenance at the right time, getting to know the machine better together, and having the right spare parts – it all makes a difference. Being able to demonstrate that effectiveness helps everyone, from management to the shop floor, appreciate the added value of this project." So, what's the impact? "The cutting machine was a real 'performance killer.' The hours lost due to technical issues with the cutting machine have dropped from 120 to 40 annually. This improvement isn't solely due to the project; daily, small improvements from both maintenance and production have also reduced the cutting machine's downtime. The targeted elimination of bad actors in the RCF, facilitated by the FMECA project, has positively affected the final result for PM2: the technical availability of the paper machine has increased from 93% (2021) to approximately 96% (2024)."

All's well that ends well, it seems. "Of course, there's room for improvement. We'll continue with the next components that could perform better, and for new projects, we're setting up maintenance and spare parts in advance using the FMECA methodology before commissioning. The collaboration between maintenance and production remains a top priority at the paper mill. We ultimately all aim for the same thing: the best production outcome," concludes Ter Schure with a smile.