Performance Study and Implementation
Alongside its day-to-day maintenance services, ANDRITZ can also analyse your mill and recommend low-cost, easy and quick potential improvements, with a small team of specialists carrying out a Performance Study and Implementation (PSI).
PSI Advantages
- Easy, quick wins - not major structural changes
- Guarantee improved performance
- Identify bottlenecks, key problems and opportunities
- Reduce unplanned problems
- Guide your maintenance to world-class performance
Proven Methodology
- ANDRITZ's global contracts feed into benchmarks and solution bank for existing problems
- Online asset condition monitoring diagnoses possible failures, increasing reliability
- Performance-based agreements, linked to maintenance and production performance
- ANDRITZ guides implementation, in partnership with your maintenance team
Case Study
At a paper mill in Brazil
ANDRITZ performed a Performance Study Implementation (PSI), one of the most complete examples in the industry. The customer has outsourced its complete mill maintenance to ANDRITZ, which supplies both full-time and part-time maintenance employees and specialists, as well as providing remote monitoring.
The customer asked ANDRITZ to carry out the PSI because there were multiple areas it wanted to improve, related to plant stability and asset reliability. Goals included training the maintenance and operation team, improving asset inspection and predictive and lubrication practices, as well as better evaluation, procedures and maintenance plans.
To do this, ANDRITZ identified issues throughout the whole pulp and paper mill, using technology tools like vibration monitoring, remote signals analysis, oil analysis and inspections. We made a critical assessment of PMs 1 and 2, utilities, coater, slitter/winder, ream packaging, rewinder and fire system, then planned the solutions in detail and solved the most serious problems.
In total, the plan included almost 12,000 points of maintenance, including automation, instrumentation, electrics, lubrication, predictive maintenance, reels, mechanicals, workshop, utilities, boiler and civil works. ANDRITZ created a methodology for managing maintenance on each process, and improved the quality and productivity of the actual performed maintenance by training the maintenance and operation team and developing the mill’s culture towards Industry 4.0, to gain productivity. This included clearly defining the roles for company employees, with thorough plans for a well-implemented process of inspections and maintenance, including predictive maintenance and a lubrication plan. Then ANDRITZ repeated the analysis, to check how it had all worked.
And it was important that it did work - not only for the customer, but also for ANDRITZ. The contract depends on the performance results that ANDRITZ delivers, so we must ensure the highest mill availability, lowest maintenance cost/ton of paper and lowest maintenance-related production losses.
In the end, it has turned out to be a win-win. Now, around 90% of planned maintenance tasks are implemented (and the trend is still rising), compared with less than 50% before. When we average out the impact on both of the mill’s paper machines, the program raised paper machine availability from 96% to 99%, doubled the mean time between failures (MTBF) and reduced unplanned shutdowns by 50%.
