Predictive MaintenanceWhat is the prize?

Degree of difficulty is on the rise Reduce marketplace redundancy The enemy is unplanned DT The prize is contribution to revenue

Predictive MaintenanceRequires a culture change

PM is not tangible Not just sending someone to karate class Every person in Operations must be

involved Mission for each department must be

understood Effective questioning We have branded our culture change

Force Field Predictive Maintenance and

Management System

1) Management Philosophy2) Predictive Maintenance Program

Accountability EnginePosition

Critical Responsibility Standard Control

Insert Operator

Insert machine productivity

Meeting the standard as established by the zone supervisor in the pre-shift meeting. Remember a standard means that anything less is unacceptable. A goal is always higher than a standard and is indicitive of exceptional performance.

Packaging Stats Report (A)

Responsibility ZonesZONE 1 4 operators ZONE 2 3 operators

D Press C Press Winder 1 B Press A PressLine Line Line Line

Winder 2Op

Winder 3

Winder 4

Op Op Op Op OpGMA 1 GMA 2 GMA 3 GMA 4 GMA 5 GMA 6

Op 3 operators ZONE 2 Op

TL 1 TL 2 TL 3 TL 4 TL 5 TL 6 TL 7 TL 8 TL 9 TL 10

CL 1 CL 2 CL 3 CL 4 CL 5 CL 6 CL 7 CL 8 CL 9 CL 10

Control ReportName: Edition: Product: Zone Plan: 2-person 3-person Zone: 1 2 3

Preshift Topics

Back-line Leader:Cartloader pre-run check performed properly

Maintained cartloaders properly

Radio called equipment problems properly

Directed work of tie-line and QC personnel

Immediate notification if procedure violated

Kept work area safe

QC Personnel: Communicated all quality issues to Insert Op.

P F P F P F P F P F P F P F

2 x's per hour

As needed

2 x's per hour

As needed

1 x per hour

Beginning of shift P F

1 x per hour P F P F P F P F P F P F P F

Procedure Execution Control

(P)ass or (F)ail

Position Responsibility Audit Frequency Audit Result

Knowledge Sharing Sessions

Engineers FF

In

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Date

Co

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Bra

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Date

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Oscillo

sco

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Date

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Packag

ing

Pla

n

Date

Co

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CT

P

Brian Boddy FF 2/6/07 FF 2/22/07 FF 3/6/07 G 3/20/07 EPat Sweeney FF Vac. FF 2/27/07 FF 3/13/07 G 3/27/07 ETim Aguier FF 2/6/07 FF 2/20/07 FF 3/6/07 G 3/20/07 E

Predictive Maintenance

Complete 2/6/07

Force Field TeamSeal of Approval

Force Field Predictive Maintenance Team

Qua

lity

and

Acc

urac

y is

Our

Pas

sion T

hank You for Y

our Contribution

Operations Division

Force Field RulesDecisions based on objective

feedbackNo complaining - useable ideas onlyNo assumptions

Force Field Steps

DT Analysis

Prioritized DT Problems

Isolate Failure Area

Determine Failure Component

Determine Control Point

Develop Troubleshooting Technique

Determine Acceptable Operating Parameters

Implement Improvement Procedure

Implement Result Monitoring of Improvement Procedure

Install Force Field Predictive Technique

Install Feedback on Force Field Violation

DT Tracking

Bucket Tracking

Determine Procedure Prob. from Holes in FF

Pub Date

Pub Day Run Presses

Planned Stops

Planned DT per Stop

Total Planned

DTActual

DTUnplanned

DT7/1/07 Sun Main 4 2 10 20 116 967/2/07 Mon Main 4 2 10 20 84 647/3/07 Tue Main 4 4 10 40 77 377/4/07 Wed Main 4 3 10 30 162 1327/5/07 Thu Main 3 2 10 20 72 527/6/07 Fri Main 3 4 10 40 60 207/7/07 Sat Main 3 2 10 20 93 737/8/07 Sun Main 4 3 10 30 102 727/9/07 Mon Main 3 3 10 30 55 25

7/10/07 Tue Main 3 3 10 30 70 407/11/07 Wed Main 4 6 10 60 136 767/12/07 Thu Main 3 3 10 30 82 527/13/07 Fri Main 3 3 10 30 122 927/14/07 Sat Main 3 3 10 30 67 377/15/07 Sun Main 4 4 10 40 80 407/16/07 Mon Main 3 3 10 30 68 387/17/07 Tue Main 3 3 10 30 64 347/18/07 Wed Main 4 4 10 40 75 357/19/07 Thu Main 3 3 10 30 71 417/20/07 Fri Main 3 5 10 50 44 -67/21/07 Sat Main 3 2 10 20 89 697/22/07 Sun Main 4 5 10 50 84 347/23/07 Mon Main 3 3 10 30 95 657/24/07 Tue Main 3 3 10 30 87 577/25/07 Wed Main 4 4 10 40 74 347/26/07 Thu Main 3 3 10 30 55 257/27/07 Fri Main 3 2 10 20 62 427/28/07 Sat Main 3 4 10 40 73 337/29/07 Sun Main 4 5 10 50 216 1667/30/07 Mon Main 3 3 10 30 34 47/31/07 Tue Main 3 3 10 30 75 45

Avg # of Presses 3.4 1020 2644 1624Total Hours 27

Pub DatePub Day

Unplanned DT Mechanical Electrical Consumable

Human (Pressroom)

Human (Maint Dept) Packaging Unknown Total

7/1/07 Sun 96 91 5 967/2/07 Mon 64 51 13 647/3/07 Tue 37 24 7 6 377/4/07 Wed 132 25 107 1327/5/07 Thu 52 48 4 527/6/07 Fri 20 16 4 207/7/07 Sat 73 62 11 737/8/07 Sun 72 8 64 727/9/07 Mon 25 13 4 8 257/10/07 Tue 40 4 36 407/11/07 Wed 76 46 21 9 767/12/07 Thu 52 14 13 12 13 527/13/07 Fri 92 15 46 8 1 22 927/14/07 Sat 37 37 377/15/07 Sun 40 13 27 407/16/07 Mon 38 8 6 5 19 387/17/07 Tue 34 16 1 17 347/18/07 Wed 35 13 22 357/19/07 Thu 41 11 15 15 417/20/07 Fri -6 -6 -67/21/07 Sat 69 16 46 7 697/22/07 Sun 34 20 14 347/23/07 Mon 65 50 15 657/24/07 Tue 57 56 1 577/25/07 Wed 34 2 29 3 347/26/07 Thu 25 11 14 257/27/07 Fri 42 42 427/28/07 Sat 33 15 18 337/29/07 Sun 166 15 35 56 60 1667/30/07 Mon 4 4 47/31/07 Tue 45 23 22 45

Minutes 1624 108 249 105 719 13 70 360 1624Percent 100% 7% 15% 6% 44% 1% 4% 22% 100%

Occurances 6 8 6 30 2 4 18 31Avg Min. per Occurance 18 31 18 24 7 18 20

Departmental Contribution to Unplanned DowntimeMinutes Percent

370 23% Predictive Maintenance Department824 51% Pressroom70 4% Packaging

360 22% Unknown1624 100%

Department

Main Edition - Sunday 7/1/07

Bucket Area Position Status Symptom Mill SpecRTP

Tension

Split Tower/

Split Sheet or Bar Lead Cause

Sub Cause Min.

Electrical B - Folder - Roll-up

Lost communic

ation - - - -Folder

Cabinet

Power supply failure 91

Human (Pressroom) A MIC Stopped - - - - -

Edition Change

Longer than

budget 1

Human (Pressroom) C MIC Stopped - - - - -

Edition Change

Longer than

budget 496

Main Edition - Monday 7/2/07

Bucket Area Position Status Symptom Mill SpecRTP

Tension

Split Tower/

Split Sheet or Bar Lead Cause

Sub Cause Min.

Human (Pressroom)

A 5-Tower A

Level Unit Start-upImpressions not on - - - - Switch

Impression

switch off 1

Unknown Unknown -Running at speed

Break - RTP B-6 Kruger Perfect 50 N/N

Unknown

Unknown 13

Human (Pressroom) Folder MkRdy Start-up

Detector shut-down - - - -

Detector

Out of alignme

nt 3

Human (Pressroom) RTP C-3 MkRdy

Running at speed

Break - RTP C-3 - - - - Belt

Not locked

in 4764

Main Edition - Sunday 7/1/07

Bucket Cause Sub Cause

PM In Place (Y/N)

If "Y" Date Done

If "Y" by

Whom

# of Component Failures on

RecordTime

Period

Mean Time

Between Failure

Predictive Maintenance Improvement

Action

Electrical Folder CabinetPower supply

failure N - - 8 2 yrs 3 months Replace all

Main Edition - Monday 7/2/07

Bucket Cause Sub Cause

PM In Place (Y/N)

If "Y" Date Done

If "Y" by

Whom

# of Component Failures on

RecordTime

Period

Mean Time

Between Failure

Predictive Maintenance Improvement

ActionNo

opportunities

Date DepartmentForce Field

Holes

Person or Position

Accountable Standard ControlDate

Started Status

8/1/07 Pressroom

Need person responsible for web detectors Make ready

Every active detector checked and problems are radio'd to engineers

Force field downtime report 9/1/07

Machinists making detector guages

8/14/07 Pressroom

Need person responsible for insuring the sheet is being pulled straight through the press Bob Dags

Each press checked every night and actions taken to correct problems

Force Field square sheet report

8/18/07 Maintenance

Need person responsible for troubleshooting standards D. Borom

8/20/07 Maintenance

Track manufacturer and date RTP belts were changed D. Borom

Every belt is tracked

Force Field RTB belt control report 8/21/07

8/20/07 Pressroom

Need person responsible for finding paster patterns that broke and evaluating the cause Bob Dags

A Press

RtpFirst

ScopeBrake Job

Pinched Wire

Carriage belts

Dancer

Cylinder

Dancer Pot.

Pot. Carrier

Slip Rings

3 4/26/07DC

8/16/07Nitta / Blue 8/15/07 8/15/07 CLEAN 8/16/07

4 4/26/07 1/4/2007 OKNitta

9/5/07 4/24/07 5/3/07 CLEAN 4/27/07

5 3/3/07DC

5/8/07 YESNitta

3/14/07 3/6/07 3/6/07 TAPE/CL 3/8/07

5a 6/24/07DC

9/12/07Nitta

9/12/07 8/15/07 8/15/07 CLEAN 9/13/07

6a 3/15/07DC

5/24/07 OKNitta

9/12/07 4/19/07 4/3/07 TAPE/CL OK

6 3/4/07 3/20/2007 YES / 5Nitta / Blue 3/20/07 3/20/07 TAPE/CL 3/20/07

7 2/19/07DC

4/18/07 YESNitta

9/12/07 2/21/07 2/21/07 RUST OK

8DC

9/12/07Nitta

9/12/07 8/15/07 8/15/07 CLEAN 9/13/07

Rtp

Slip Ring

BrushesWarner

AdjWarner

ReplMotoriz'd Reg.

Transducer

Volume Booster

1395 Drive

Final scope

3 8/16/07 8/15/074 4/27/07 511/07 5/16/07 4/24/07 4/24/07 4/24/07 OK 6/19/075 3/8/07 3/14/07 3/9/07 3/7/07 3/6/07 3/7/07 3/20/07 3/16/07

5a 9/13/07 8/15/076a 4/4/07 OK 4/19/07 4/3/07 4/3/07 OK6 3/20/07 OK CAL. 3/21/07 3/21/07 3/20/07 4/25/077 3/2/07 3/14/07 4/19/07 CAL. OK 2/21/07 OK 4/21/078 9/13/07 6/26/07 8/15/07 6/27/07

Reducing Unknown DT Dancer positionDover roller tensionFolder and unit detectorsPaster brush, bell and knifeUnit severers

ResultsRTP tension RPB from 25 to 400Reduced out of alignment detector

shutdowns by 90%Pressroom accountable for self-inflicted

DTUnknown DT being reduced by

electronic snapshotEvery DT event; procedure vs FF hole