Avesta World Class Maintenance

1. Avesta World Class Maintenance AWCM � Juni 2008

2. 2 | September 19, 2012 | Avesta Jernverk, Teknisk Service Table of contents Welcome and introduction Outokumpu The Avesta Works site Backgrounds � �Our way to world class maintenance� Our Maximo history Maintenance analysis Measures implemented today Results Questions & Answers

3. 3 | September 19, 2012 | Avesta Jernverk, Teknisk Service Outokumpu Stainless steel manufacturer One of the world�s fourth largest producer Operates in 30 countries with plants in Finland, Sweden, Britain and US 8 000 people employed HQ in Espoo Finland

4. 4 | September 19, 2012 | Avesta Jernverk, Teknisk Service The Avesta Works site Located in Sweden Steel production started in Avesta in 1883 Steel mill for stainless steel coils Steelwork, Continuous Casting, Hot Rolling shop (Steckel Mill), Cold rolling and Completion line Currently 1�000 employees Largest company in the region A �Technical Services� department containing 95 people. Maintenance engineers, experts and mechanics and electricians. Have a 1.5 billion dollar investment coming up during the next 5 years. This will give a completely new plant which is going to double the amount of assets and raise the requirements on an effective and well balanced maintenance.

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8. 8 | September 19, 2012 | Avesta Jernverk, Teknisk Service Flexible tubes Today all manufacturers of flexible tubes uses duplex stainless steels LDX 2101 2304 2205

9. 9 | September 19, 2012 | Avesta Jernverk, Teknisk Service Backgrounds � � Our way to world class maintenance � Avesta Works has a long tradition of actively working with an effectice maintenance organisation. A maintenance analysis was performed in 2006 containing. An overall analysis of the maintenance work. A number of actions were proposed to improve the maintenance activities to a world class maintenance: Maintenace ,vision and strategy Create a more accurate follow-up, i.e. better documentation and new KPI�s that are close to the assets and workers Get continious improvement philosophy in place. It is now time to evaluate what these actions has given in terms of increased equipment up-time and output quality; optimized labor efficiency and equipment maintenance.

10. 10 | September 19, 2012 | Avesta Jernverk, Teknisk Service Our Maximo history First installation in 1994. Maximo 2,1 Upgraded to Maximo 3.11 in 1999 Upgraded to Maximo 4.01 in 2002 Upgraded to Maximo 6.2. in 2007 (Today 6,2,2) Currently running a very standardized solution 500 users where of 100 concurrent Integrations with SAP, Production systems (for workorder creation) Meridian ( drawings ) Met-Online (hand held) Automated inventory (Pater noster) Documents and drawings shown on screen in Maximo Hand held devices for Work order (routes, job plans, reporting etc.) Inventory (stock taking, issues & returns, receipts etc) Maximo Data Loader for adding data to the system

11. 11 | September 19, 2012 | Avesta Jernverk, Teknisk Service Maintenance analysis Master Thesis within maintenance and reliability Named the best Master Thesis within maintenance and reliability in 2003. Contained two major topics A technical model for assessing vibrations and their affect on machine reliability. An overall analysis of the maintenance work. A number of actions were proposed to improve the maintenance activities aiming at: Create a more accurate follow-up. Get continious improvement philosophy in place. Create a world class maintenance.

12. 12 | September 19, 2012 | Avesta Jernverk, Teknisk Service Proposed measures New KPI�s Machine close KPI�s that the workers easily can understand and influence . Machine close KPI�s that can be aggregated into higher level KPIs MTBF, MTTR etc can be aggregated into OEE (Overall Equipment Efficiency) PM/CM quote Improved communication and documentation between different parts of the business Project for better attitudes

13. 13 | September 19, 2012 | Avesta Jernverk, Teknisk Service Measures implemented today Machine close KPI:s in Start Center and intranet. Other maintenance KPI:s on webb Hand held solution for work orders and inventory Grab hand held, go Route, read Job plan, enter workorder For inventory as well Drawings and documents shown in Maximo AWCM � Avesta World Class Maintenance Project for tuning the maintenance processes and activities. OK>1 Tool for continious improvements implemented throughout Outokumpu on initiative from the CEO. Carried out in cross functional teams to improvements. Communication and documentation emphasized in the OK>1 project. �Reflection� groups for discussing attitudes and treatment

14. AWCMAvesta World Class Maintenance Oktober 2008

15. 15 | September 19, 2012 | Avesta Jernverk, Teknisk Service Bakgrund F�ljande f�rb�ttringsomr�den f�r Avesta p�visades i den analys av underh�llsarbetet i koncernen som ABB gjorde tidigt 2006: Gemensamma m�l mellan produktion och underh�ll vad g�ller nyckeltal och ansvarsomr�den. S�rskilja kostnader f�r underh�ll, modifieringar och f�rb�ttringar. �vergripande strategier f�r hur f�rebyggande underh�ll ska genomf�ras och hur underh�llsresurserna ska f�rdelas. Utnyttja m�jlig flexibilitet och utveckling genom utbyte av resurser, erfarenhet och kunskap mellan verken. Anv�ndning av underh�llssystemet f�r felanm�lan, arbetsorder, avrapportering och underlag till uppf�ljningar och analys

16. 16 | September 19, 2012 | Avesta Jernverk, Teknisk Service Beslut fr�n ortsledningen Underh�llet f�r Avesta Works ska f�lja beslutade ekonomiska riktlinjer Ett underh�ll i v�rldsklass beh�vs f�r att Outokumpu ska bli den obestridde ledaren inom rostfritt Att underh�lla v�r produktionsutrustning �r en del av v�r k�rnverksamhet V�rt eget underh�ll ska alltid vara kostnadseffektivare �n underh�ll fr�n extern leverant�r Vi ska anv�nda OK 1 och AWCM projekten f�r att uppn� v�ra m�l

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18. 18 | September 19, 2012 | Avesta Jernverk, Teknisk Service Utvecklingsprocessen mot underh�ll i v�rldsklass

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20. 20 | September 19, 2012 | Avesta Jernverk, Teknisk Service F�lja planen f�r inf�randet av OK1 PM ortspelare �r styrgrupp f�r AWCM och ansvarar f�r samordning mot OK1 arbetet AWCM deltar som PECA i PM och AM pelare f�r St�lverk, Varmband och KBR ( Peca = underh�llsspecialist) AWCM ansvarar f�r att: S�kerst�lla ett gemensamt arbetss�tt f�r hela Avesta Works Ut�ka antalet underh�llsingenj�rer med spetskompetens (idag 10st ) Ta hj�lp av externa resurser f�r att driva genomf�rande (Idhammar, SKF) Arbeta f�r en orts-/koncerngemensam syn p�: Metodstandard (OK 1= Operational exellense ) Systemstandard Nyckeltal (EFNMS Europeean Federation of National Maintenance Societies) Genomf�rande

21. 21 | September 19, 2012 | Avesta Jernverk, Teknisk Service Underh�llsorganisationen m�ts och f�ljs upp

22. 22 | September 19, 2012 | Avesta Jernverk, Teknisk Service Orts PM-pelare M�l (att f�rb�ttra) Underh�llskostnad Antal haverier Teknisk tillg�nglighet Funktionss�kerhet (MTBF) Underh�llsm�ssighet (MTTR) Underh�llss�kerhet (MTW)

23. 23 | September 19, 2012 | Avesta Jernverk, Teknisk Service Genomf�rda f�rb�ttringar Vi har nu en underh�llspolicy med vision, strategi och uppdrag Vi f�ljer v�r Underh�llskostnad genom dokumenterad standard Underh�llsnyckeltal f�ljs p� score webben (4 st) UH terminologi enligt standard SS-EN 13306 (dok) Nya rapporter har tagits fram f�r att st�dja pelarnas analysarbete Beskrivning av UH processerna Genomg�ng av anl�ggningsstruktur samt ABC klassning �r genomf�rd p� verken Vi redovisar tid och �tg�rd, uttag av material b�de externt som internt p� arbetsorder f�r att kunna f�lja kostnader p� v�ra utrustningar OK-1 arbetet ig�ng p� alla verk 5 UH ingenj�rer g�r PECAT utbildning, 3 �r utexaminerade

24. 24 | September 19, 2012 | Avesta Jernverk, Teknisk Service Underh�llspolicy

25. 25 | September 19, 2012 | Avesta Jernverk, Teknisk Service Idag vet vi vilka utrustningar som �r viktigast att underh�lla

26. 26 | September 19, 2012 | Avesta Jernverk, Teknisk Service ABC klassning av produktionsutrustning Idag vet vi vilka utrustningar som �r viktigast att underh�lla

27. 27 | September 19, 2012 | Avesta Jernverk, Teknisk Service Nyckeltal � styrning av underh�ll

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29. 29 | September 19, 2012 | Avesta Jernverk, Teknisk Service Nyckeltal - hur m�r v�r produktionsutrustning?

30. 30 | September 19, 2012 | Avesta Jernverk, Teknisk Service Underh�llsprocesser

31. 31 | September 19, 2012 | Avesta Jernverk, Teknisk Service P�g�ende Q3�Q4 2008 Planering/beredning av underh�llsarbete samordnas genom arbete i OK-1 och AWCM. Viktiga �terkommande underh�llsarbeten bereds som s.k. �job plans� vilket inneb�r att. Vi vet hur l�ng tid arbetet b�r ta Vilka reservdelar som beh�vs Vilka ev. ritningar och �vriga dokument Vilka ev. externa tj�nster som erfordras Vilka ev. verktyg som erfordras Reservdelsoptimering f�r �kad underh�llss�kerhet, OK-1 team i samarbete med orts PM-pelare och AWCM. F�rnyad underh�llsanalys (SKF) f�r att m�ta v�ra f�rb�ttringar och identifiera kvarvarande brister

32. 32 | September 19, 2012 | Avesta Jernverk, Teknisk Service Utmaningen! Forts�tta att arbeta f�r �Avesta Underh�ll i V�rldsklass� och se till att f�rb�ttringarna blir best�ende F�rdjupa samarbetet mellan produktion och underh�ll inom OK1 f�r att st�dja kunskaps�verf�rande och inf�rande av operat�rsunderh�ll H�lla v�r budget f�r underh�llskostnader S�kerst�lla att vi har b�sta t�nkbara systemst�d f�r underh�llsverksamheten och dess st�dfunktioner (ink�p, f�rr�d etc.)

33. 33 | September 19, 2012 | Avesta Jernverk, Teknisk Service Results KPI�s under development for Start Center i Maximo Exempel fr�n Travers underh�lls chef. Maximo startcenter Jonas Back / IBM i version 6.2 �ke Burman Outokumpu visar hur man kan f�lja sina utrustningar vad g�ller kostnader, milj�krav, besiktningar mm i Maximo. Men �ven hur man enkelt med SQL- fr�gor har kontroll p� sitt system.

34. 34 | September 19, 2012 | Avesta Jernverk, Teknisk Service Questions & Answers