Maintenance Excellence to evaluate the efficiency and effectiveness of the maintenance department

Smurfit Kappa is one of the leading providers of paper-based packaging solutions in the world with over 43,000 employees across 33 countries and with revenue of €8.1 billion in 2014. With their pro-active team they relentlessly use their extensive experience and expertise, supported by their scale, to open up opportunities for their customers. They collaborate with forward thinking customers by sharing superior product knowledge, market understanding and insights in packaging trends to ensure business success in their markets. Annually, Smurfit Kappa Roermond Papier processes 600,000 tons (1 million bales) of waste paper into new paper roll. This is more than 25% of what the Netherlands annually collects. The end-product is raw material for corrugated board. The Roermond plant is part of Smurfit Kappa Recycled Paper Europe, a cluster of 6 paper plants within the international Smurfit Kappa Group.

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Project description and goals

A complete and detailed analysis of Maintenance Excellence to evaluate the efficiency and effectiveness of the maintenance department at Smurfit Kappa Roermond Papier, in order to indicate improvement potential. Goals are:

  • Defining optimization points
  • Indicating optimization actions

Project approach

PDM executed the following things:

  • A strategic study: analyzing and benchmarking the maintenance excellence level
  • A process and system study: analyzing the various maintenance activity processes and the maintenance management control and reporting system
  • An operational study: analyzing leadership/management competences, compliance in behavior, hands on tool time, efficiency

Project results

  • Improved hands on tool time resulting into less contractor costs, less backlog and less production loss
  • Better budget control resulting into less costs and waste
  • Risk and cost effective spare part and warehouse management resulting into higher availability and lower costs (stock value)
  • Better insight into and understanding of the maintenance activities within the plant
  • Proposal plan for implementing the defined improvements
Wouter Lap
Manager Operations, Smurfit Kappa Roermond

PDM executed a complete and detailed analysis about Maintenance Excellence to evaluate the efficiency and effectiveness of our maintenance department in order to indicate improvement potential. The result was a clear, objective, facts and figures based evaluation. Improvement potential is clearly indicated together with a proposal for next steps.