Five Ways to Eliminate
Unplanned Downtime

Eliminate Unplanned Downtime

Over an eight month period, Roseburg Forest Products saved $472,000 in downtime costs at a single facility by implementing best practices and using Augury’s Machine Health solution.

Brian Richmond is the Regional Reliability Manager at Roseburg, and previously served 20 years in the U.S. Navy, where he was a Maintenance and Program Manager for nuclear submarines.

Here are Brian’s battle-tested
best practices:

1.Write a Playbook

Roseburg spent a year working with external and internal experts to write a comprehensive playbook for maintenance and operations staff. The final document was over 300 pages long and included the following:

  • How Roseburg identifies work, what that work looks like and how the work is done
  • The workflow to assign work to operators and technicians
  • How to plan a shutdown
  • Metrics: Roseburg uses around 21 leading and lagging indicators

2.Stop Firefighting

One of the goals of writing a playbook was to shift the team away from firefighting to proactively planning work. “We want to run the plant. We want to stop the plant running us,” says Brian.

  • Stop rewarding a maintenance culture where everybody wants to be the hero by fixing something today. If it’s not an emergency repair, plan to fix it properly tomorrow.
  • Encourage proactive behaviors with KPIs like Mean Time Between Failure, schedule compliance and time spent on proactive versus reactive work.
  • Shift some of the time saved from reactive work to root cause analysis

3.Keep Shutdowns within Schedule

Uptime starts to suffer when shutdowns consistently extend beyond the planned window. Don’t assume that every issue you find during a shutdown has to be fixed immediately. Better planning of maintenance tasks also drastically improves safety.

  • Plan who is doing what, when, where and how and always have the necessary tools and parts on hand
  • Evaluate each issue found. Can this machine run safely until the next shutdown? If it can, don’t fix it now
  • Unless an issue found during a shutdown critically affects safety, quality or production, stick to the agreed work schedule for the shutdown

4.Do Precision Maintenance

Maintenance tasks should be done the same way every time. This eliminates variability in the maintenance process and makes it much easier to pinpoint the root causes of a failure.

  • Write in-depth procedures in the playbook so jobs are always done the same way
  • Use Augury’s Machine Health solution to identify sites with ongoing misalignment, bearing wear or balance issues
  • Train staff at those sites to use laser alignment tools, torque wrenches and other precision techniques

5.Use Condition-based Monitoring

Condition-based monitoring helps facilities to stop firefighting, keep shutdowns within schedule and identify where precision maintenance is needed. Roseburg uses Augury’s Machine Health solution to help identify equipment that is starting to fail and how to fix it.

  • Use Machine Health to prioritize maintenance tasks and get at-risk machines out of danger fast
  • Don’t just look at the fault diagnosis; look at the trend. Add more frequent monitoring if necessary
  • Use Machine Health to validate that a repair has actually fixed an issue

Interested in Diving Deeper?

Check out Brian's webinar on How To Eliminate
Unplanned Downtime