Workshop A
Reliability Based Spare Parts and Materials Management
This workshop focuses on building a partnership of your Maintenance and Storeroom professionals with a common objective of maximizing plant reliability through logical and efficient management of the spare parts, materials, and the information required by maintenance people. The importance of integrating the reliability management process with the optimization of spare parts is emphasized.

Don Armstrong
Senior Reliability & Maintenance Consultant
IDCON, INC., Raleigh, NC

Workshop B
Planning, Scheduling and Control of Reliability and Maintenance
Good planning and scheduling enables the implementation of all other maintenance efforts, including a reliability improvement process. This workshop emphasizes the importance of a cooperative operations and maintenance partnership, and how planning and scheduling helps this partnership to achieve lasting results. Examples of "best practices" and practical tips for implementing planning and scheduling changes are included.

Don Armstrong
Senior Reliability & Maintenance Consultant
IDCON, INC., Raleigh, NC

Workshop C
A Dime for a Dollar: Finding Value in Reliability Centered Lubrication
Running an advanced reliability strategy with the ‘same-old-lubrication’ strategy is equivalent to using retreads on a Maserati.  Regardless of how carefully you tune the engine, or drive the racetrack, you will always be limited by the rubber on the road.  Likewise, it is impossible to approach best of class in mechanical reliability while trying to overcome the degrading effects of a mismatched lubrication practice. Is it time to move toward the lifecycle enhancing benefits of reliability centered lubrication practices? Come and see how to measure the value.

Mike Johnson, CMRP
Principal Consultant
AMRRI, Franklin, TN

Workshop D
Operator Based Reliability and Preventive Maintenance
Learn the basic concepts to prevent and detect early equipment failures from the perspective of operations and maintenance. Discover how operations process care relates to maintenance equipment care. Do you want a better understanding of the design of a cost effective preventive maintenance system for operations and maintenance? This workshop will include a discussion of a failure developing period, life of components, consequence of failure analysis and the following topics:

• Integrated Reliability – joining your preventive maintenance with operator based reliability
• Maintenance and reliability processes and their interaction
• Financial impact of preventive maintenance for operations and maintenance
• Operator procedures and equipment failure relationship
• Maintenance prevention techniques
• Condition monitoring techniques
• Selecting the most cost effective preventive maintenance method
• Inspection frequencies
• Equipment life
• Who (operations or maintenance) should do what PM task
• Setting up project mission, vision, scope, and goal
• Documenting the preventive maintenance system, set expectations, and streamline process
• Key performance indicators
• Exercises

Workshop E
Root Cause Problem Elimination for Operations & Maintenance Frontline IDCON believes that 80% of all problems can be solved by the frontline operations and maintenance hourly, supervisors, and planners. To implement Root Cause Problem Elimination in a plant/ mill, it is necessary to design a simple, yet effective model.
This workshop will teach you the basics of critical thinking, trouble shooting, and root cause analysis. Learn a step-by-step effective process that can be taught and easily understood on the shop floor. Several exercises to illustrate and practice root cause problem elimination will be presented along with the following topics:

• Summary of root cause problem elimination
• What is a problem
• Finding Problems
• Triggers
• Defining a problem
• Collecting information
• Establishing Potential Causes
• Identify Possible Solutions
• Analyze and Select Best Solution(s)
• Validate the Solution
• Document, train and Implement the solution
• Integration of Root Cause problem Elimination and planning and scheduling
• Integration of Root Cause problem Elimination and preventive maintenance
• Operations, Maintenance, and engineering in root cause problem elimination
• Exercise

Michael Lippig
Senior Reliability & Maintenance Consultant
IDCON, INC., Raleigh, NC

Results Oriented Reliability and Maintenance 2006
 - RORM 2006
This seminar has become an institution for operations and maintenance professionals in the Pulp and Paper industry. Over 100 plants worldwide have included this RORM seminar as a part of their improvement initiatives. Since it was first included in this conference in 1988, it is updated annually to address latest findings and observations. This seminar is consistently rated “best of all” in this event, in addition to, other events around the world. Last year the seminar was rated 9.45 on a scale of 10. For optimal benefits, we encourage you to attend this seminar, together, with representatives from operations and maintenance leadership, as well as, crafts people. Seminar topics are updated up to the week prior to the conference and will include, but not be limited to:

• Key elements of successful and sustainable reliability and maintenance improvements
• Why many initiatives do not deliver projected savings
• Methodology to estimate potential savings and financial return  
• Necessary changes and paradigm busting
• Key elements of the Operations, Maintenance, Engineering partnership
• Reliability mathematics
• Operators in maintenance
• Why most planners do not plan
• Selling your improvement initiatives to top management. Reliability impact on Return On Net Assets (RONA)

Christer Idhammar, President
IDCON, INC., Raleigh, NC

Saving Energy Through Maintenance

Robert Bates
Manager, Product Technology and Applications
Metso Paper, Thunder Bay, Canada

Break

Introduction and Opening of Conference

Christer Idhammar
President
IDCON, INC., Raleigh, NC

Hedgehog or Fox?

• World class reliability and maintenance excellence are necessary for a manufacturing company to achieve and sustain success.
• There are no secrets to excellence in reliability and maintenance. It is a matter of constancy of purpose. Must have the passion and focus of a hedgehog!
• Set realistic timelines and practice patience. Must not become scattered and defused like a fox!
• Need a champion with the passion to justify value of maintenance excellence and reliability to senior management.
• Must seek perfection! The journey never ends!

John B. Crowe
President & CEO
Buckeye Technologies, Memphis, TN

”The Future of the Market Pulp Business - Can We Compete?”
Currently, the North American pulp producer is not competitive with South American producers, specifically, the Brazilian producers. Their advantage is:

• cheap, fast growing fibre
• cheap labor
• higher yield
• close proximity to shipping
• modern facilities with high production capability
• new technologies

Some of our challenges are:

• insufficient capital reinvestment in our North American plants
• government taxation policy and depreciation
• utilization of current technology is lacking
• expensive wood costs
• high labor costs

How will a mill like Alberta-Pacific Forest Industries compete? Focusing entirely on cost reduction as a strategy can cripple a plant and reduce their ability to compete. Organizations need to re-think how they currently do business. Focusing our attention on waste reduction is more meaningful. Every employee needs to consider the value they add when performing a certain function. New technologies that can be readily implemented and have a high rate of return, need to be considered when developing short and long term plans.

Daryl Nichol
Vice President
Alberta-Pacific Forest, Industries, Inc. Boyle, Alberta, Canada

“Key Concepts and The Human Factor of The Successful Work System at Solvay Paperboard”

Thomas Stigers
Vice President
Solvay Paperboard, Syracuse, NY

Case Study
“Safety: Planned and Scheduled Maintenance”
Studies have confirmed there is a strong correlation between reactive maintenance and safety incidents. This presentation will discuss a case study on the importance of planning and scheduling work to avoid safety incidents.

John Martin
Maintenance & Engineering Training Coordinator
MeadWestvaco Corporation
North Charleston, SC

Case Study
“Current Best Reliability and Maintenance Practices: What They Are and How to Use Them to Evaluate and Improve Performance”
Mahatma Gandhi was once asked what he thought of western civilization. He replied that he thought it would be a good idea. The same thought, comes to mind, when considering management skills in maintenance departments. It is not uncommon to find maintenance departments without established goals and visions. The action plans to reach the goals and to follow the vision are equally void. In this case study, learn some valuable tips on how to establish basic leadership processes in your mill. 

Torbjorn Idhammar
Vice President & Partner
IDCON, INC., Raleigh, NC

Case study
“Using Current Best Practices: Maintenance Transformation for Safety, Reliability, and Cost Reduction”
The maintenance audit process uses CBP’s to create a “mill process” which includes an operations and maintenance partnership with ownership in improved Safety, OME, and cost reduction. This process has basic elements as a foundation and weaves a common theme of production improvement throughout maintenance and operations.

Robbie Coleman
Maintenance Manager
Smurfit Stone Corporation
West Point, VA

Opening Reception

Closing of Exhibits and Raffle of Prizes
(You must be present to win)

Track A- Presentation 1

Case Study
“Maintenance Budget. How to Develop a Realistic Maintenance Budget and to Use it to Control Spending”
Developing and meeting a maintenance budget target begins with the identification of a good task list, which, if addressed throughout the year, drives the outage requirements. Each area must identify routine cost, major maintenance cost, and extraordinary cost to determine the monthly requirements. Daily spending reports provide a continuous update on budget targets and ensure responsibility and accountability.

Robbie Coleman
Maintenance Manager
Smurfit Stone Corporation
West Point, VA

Track B- Presentation 1

“Water Contamination of Lubrication Oils – The Invisible Enemy of Equipment Reliability”
Water contamination in oil lubricated equipment has long been recognized as a leading cause of oil degradation and premature equipment failures. Different technologies exist for detecting and removing the visible phases of water in oil, but damage to bearings and lubricants occur prior to reaching visible levels. 

Learn how Saturated Relative Humidity sensing technology can be used to monitor the headspace prior to reaching damaging levels. In many large re-circulating oil systems, water is the primary contaminant and “real time” warnings to increasing levels could allow for corrective action prior to requiring expensive removal techniques.  Strategically placed sensors can lead right to the culprit of the moisture ingression, such as a damaged seal.  

Rojean Thomas
Manager of Engineering
Trico Manufacturing, Pewaukee, WI

Track A- Presentation 2

“The Impact of Precision Alignment on the Life of Bearings and Seals”
Precision alignment of rotating machinery shafts is one of the key factors in reducing “parasitic” loads on bearings, seals and shafting, thus increasing overall machine uptime, Mean Time Between Failure (MTBF) of machinery components, and profitability of the organization. The primary focus of this presentation is to show how misalignment affects the machine components of both the driver and driven machines once coupled and under operation.

Michael L. Snider
CEO
Universal Technologies’ Companies
Huntersville, NC

Track B- Presentation 2

“Preventive Maintenance For Electrical and Instrument Equipment – A forgotten Opportunity?”
Discuss the experiences of developing and implementing a successful maintenance program, specifically, the Automation maintenance practices. Automation maintenance development in some companies is not a focus; therefore, hinders the organizations’ success.
In our industry, automation maintenance is an opportunity to provide organizations with a comparative advantage in the marketplace. Some Corporations have restructured their maintenance organization to develop a world class maintenance program. The process, learning steps, current practices, and future goals of the maintenance program will be reviewed with a focus on Automation. Learn best practices and opportunities for a successful preventive maintenance program.

Steve Holmes
Reliability & Automation Superintendent
Georgia-Pacific Corporation, Rincon, GA

Track A- Presentation 3

Case Study
“Operations and Maintenance: Bridging the Gap to Operations Excellence”
Learn how the Georgia-Pacific Corporation facility in Palatka, Florida is bridging the gap to “Operations Excellence” by using an existing essential care route for operators to take ownership in their equipment. Recently, Georgia-Pacific was purchased by Koch Industries, and as a result, the mill is currently going through rapid changes. Jobs and functions are being streamlined to produce maximum efficiency and 10,000% compliance = 100% of the employees, 100% of the time.

Paul Dufresne
Maintenance Engineer I
Georgia-Pacific Corporation, Palatka, FL

Track B- Presentation 3

The skill sets have and will continue to decline, as a result of, significant staffing cutbacks, over the past 15 + years, combined with the fact baby boomers will begin to retire in droves, in 2008. The industrial maintenance organization of the future will increasingly come to resemble maintenance organizations that serve commercial aviation and nuclear power industries - heavily dependent upon procedures to define what and how a job is accomplished. Learn the key elements to develop, deploy, and deliver an effective procedure-based lubrication program.

Mark Barnes, Ph.D., CMRP
Vice President
Noria Reliability Solutions, Vancouver, BC, Canada

Track A- Presentation 4

Case Study
“First Steps to Reliability”
This presentation will address the use of software and mobile handheld computers for maintenance and operator basic care equipment inspections. Jim illustrates how the company aggressively pursued a culture change to structured reliability in order to significantly minimize downtime in a plant with over 15,000 pieces of equipment. Learn how Tembec used their limited resources to gain considerable improvements and cost reduction through reliability techniques such as Condition Based Monitoring and Vibration Analysis. Jim implemented the Design Maintenance software application, MAINTelligence, in 2003. Their plant utilizes nine Intermec 700 handhelds.

Jim Hudson                  
Reliability Superintendent
Tembec, St. Francisville, LA

Track B- Presentation 4

Case Study
“Improving Reliability and Production Yield by Creating an Automation Department”

• Why create an automation Department?
• Assess the potential for automation in the plant
• Lead the plant into the future by integrating automation with existing Electrical/Instrumentation skills

Simon Fitzgerald
Sr. Electrical & Controls Engineer
Louisiana-Pacific Corporation
Roaring River, NC

Track A- Presentation 5

“Maintenance Management Experiences, Lessons Learned & Opportunities to Bring Maintenance into the Business”
Explore the experiences of a Maintenance Manager, Supervisor, and “Change Agent” in the Pulp & Paper industry. 
Follow the process: from the need for change, the presentation of the case for change, the improvement or modernization, and finally, the implementation phase. Learn what worked, what didn’t work, and how to discern the “gray” area in this critical change management process. Discuss how to appropriately, effectively, and at the right time, leverage technology in day-to-day reliability management and the tactics to manage the evolution from a culture of fire-fighting, to planned & scheduled maintenance.

Tom Woginrich
Senior Consultant
IBM Global Business Services, Newberg, OR

Track B- Presentation 5

“Standardizing and Improving Best Practices in Estimating and Planning”
Even though planning and estimating are considered the foundation for turnaround management success, studies reveal the quality and definition of plans and estimates vary greatly, even among experienced planners. The level of detail ranges from 3-26 tasks, for one particular test case, with a total job duration ranging from 4-38 hours! With standardized, consistent, planning and estimating, management would have a more reliable measuring stick for evaluating project deviation and its’ success.

Standardization and a solution to capture and to improve best practices are necessary to refine the quality of planning. Currently, most planning departments plan and estimate jobs manually or use a library of static templates that must be customized for the instant project. Both methods have serious limitations as a mechanism for capturing lessons learned and for improving best practices for future projects. This presentation will outline:

• Research on inconsistent planning quality
• Problems inherent in the manual or static template based approach to capturing and improving best practices
• Solutions to some commonly identified problems

Bernard Ertl
Vice President
InterPlan Systems, Inc. Houston, TX

Track A- Presentation 6

Case Study
“Capturing The Knowledge of Your Aging Work Force and Planning For The Future Shortage of Skilled Technicians”

• Assist your organization in hiring people who have learning capacity and aptitude to get you to where you need to be tomorrow
• Identify the specific knowledge and skills required to maintain equipment
• Capture the knowledge and skills of your incumbent technicians and identify the gap between required and existing skills-sets
• Develop specific training that will provide the knowledge and skills required to maintain equipment

David Crockett
President & CEO
CenTec Inc., Greenville, SC

Track B- Presentation 6

“Effective Predictive Maintenance for Pumps”
Keeping pumps operating successfully for long periods of time requires careful pump design selection, proper installation, careful operation, the ability to observe changes in performance over time, and in the event of a failure, the capacity to thoroughly investigate the cause of the failure and take measures to prevent the problem from reoccurring. Pumps that have been properly sized and lubricated, dynamically balanced, sit on stable foundations with good shaft alignment, are carefully started, operated, stopped, and observed by maintenance personnel for unhealthy trends to appear, and acted on immediately, usually, never experience a catastrophic failure. This is true for a large percentage of pumping systems; however, not true for all pumps.
Discuss how frequently pumps are:

• Asked to operate way off their best efficiency point
• Perched on unstable base plates
• Run under moderate to severe misalignment conditions
• Lubricated at the factory and failed to see another drop until the bearings had seized and vibrated until the bolts had come loose
• Replaced with new parts, when the pumping ceases, with no speculation to why the failure occurred

Learn the four maintenance philosophies, their strategic and financial differences, and a 10 point disassembly checklist to assist in the detection of the cause of the failure.

John Piotrowski
President & Owner
Turvac, Incorporated, Oregonia, OH

Track A- Presentation 7

 “Maintenance & Troubleshooting Techniques for Hydraulic Systems”

The use of hydraulic systems has increased dramatically over the last fifteen years. Hydraulic systems can be found in every production phase from the wood yard, to the power house pulp mill, and to the paper machine. Learn how a successful hydraulic system can increase productivity through the basic function, service life, failure modes, and required maintenance.

Thomas Tipton
Field Operations
KAM Tech, Conroe, TX

Track B- Presentation 7

“Six Fault Zones of an Electric Motor”
When analyzing a motor, sometimes a Resistance to Ground test, is not enough.  With today’s complex motor designs, it is important to look at your motors using the comprehensive Six Fault Zone Approach; Rotor, Stator, Air Gap, Power Circuit, Insulation, and Power Quality. This unique approach can effectively identify problems allowing you to fix them before they become catastrophic. In this presentation, we will explore the benefits of DC motor testing from both static and dynamic testing.

Noah Bethel
Product Development Manager
PdMA Corporation, Tampa, FL

Conclusion and Closing of Conference
Raffle/Prizes (You must be present to win)