Introduction of an integrated maintenance system in the tissue paper sector: a case study

The paper presents a methodological approach aimed at introducing an integrated maintenance system at a papermaking plant operating in the tissue & towel sector. The described approach led to a complete redesign of plant maintenance operations relying on both technical and managerial actions. The re-engineering of maintenance activities was focused on the continuous paper machine and included a thorough preliminary extraordinary maintenance program, the implementation of a daily schedule of condition monitoring activities, the development of a specific software tool for data analysis, and the introduction of revised maintenance activities based on newly identified critical check points. In particular, the problem of felt management has been addressed which has a significant economic impact on operational costs. Adopting the described paper machine maintenance management plan it has been possible to nearly double the average felt life, passing from 30 to 60 days. In this way significant economic savings are expected, up to 100,000 euros per year, and a reduction of machine downtime results leading to an increased plant productivity.