Operator-driven reliability programme does it for Stora Enso 05 April 2012

Global paper, packaging and wood products firm Stora Enso is reporting significant benefits since introducing SKF's operator-driven reliability (ODR) programme.

Juha Helkala, maintenance director at Stora Enso in Finland, explains that by using control and monitoring technologies in tandem with SKF's planned maintenance methodology, maintenance efficiency has improved, resulting in increased machine availability and reduced operating costs.

The improvements have been realised at its Varkaus pulp and paper mill, which produces fine paper and newsprint, as well as recycling milk and juice cartons. Unplanned downtime on PM3 (paper machine line three) had been affecting productivity – and hence the ODR programme.

Jani Markkanen, an ODR specialist from SKF, explains that initially, a pilot project was set up, with a steering group laying the foundation. "It is extremely important to be clear on everything and that your goals are well defined,"

He says that ODR specialists from SKF ensured that machinery operators received a two-hour theoretical introduction, with a two-hour walk through on-site. They also provided reliability tools so that they were empowered to play a proactive role in machine maintenance.

All operators also received an SKF Microlog Inspector handheld computer with a wireless machine condition detector to record day-to-day data.

Information is now uploaded using the SKF @ptitude Inspector software package, where the data can be analysed, reported and shared across the plant. Markkanen says it's all about systemising and spreading maintenance within a proactive, can-do environment.

It's also about better using time by avoiding fire fighting, meaning that machine shift operators can now spend time discussing potential problems with maintenance teams around the PM3 machinery, and identifying priorities.

Helkala says that the initial investment paid for itself in the first month and now, Stora Enso is implementing the programme across its remaining Varkaus units, as well as the company's other Finnish plants.

"Looking forward, operator maintenance is one of our strategies, and the ODR programme has provided a framework for improved inspection, recording of data, communication and response times that have led the Varkaus plant to maximise productivity levels, manage risk levels and minimise running costs," she states.

Brian Tinham

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