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You will never know if a mill is well maintained if you follow the mill's "tour route"--you know, the route they keep clean and in great shape for executives, board members and customers. Didn't know that mills have "tour routes"? Have I got some hot property in Florida for you!

In a mill that is in really bad shape, you won't have to go to the places I am going to tell you about, for they, that is those in charge, will never let you get there.

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Maintenance Month Platinum Sponsor:

RMR Mechanical: We perform as planned! Visit us at www.rmrmechanical.com!

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Thus, the first clue you are in a poorly maintained mill is if you run into resistance to a full blown tour. The first time this happened to me was when I was taking my dad on a tour of a mill in which I worked, a private tour I was giving him on a Saturday. The pulp mill superintendent insisted that I not bring him through the pulp mill.

Of course, I already knew why--the pulp mill was a wreck and, by the way, that superintendent was soon gone, despite having what at the time were considered the best credentials one could have in this industry.

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Maintenance Month Silver Sponsors:

Fulton Systems: Our designs are built on proven methods and technology. www.fultonsystems.com.

CR Meyer & Sons: CR Meyer takes pride in building complete new facilities and maintaining them long after they are completed. www.crmeyer.com.

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All that aside, here is where you want to go if they will let you.

1. If there are remote wells or a remote water intake from a river--go there. If the equipment there looks like someone loves it, you are in a well maintained mill.

2. Likewise, check out the effluent system. And, again, if it looks well maintained, you are in a mill that is in good shape.

3. Don't be fooled by unit operations such as lime kilns. They may seem to be "backwater" locations, but if these things don't run to their highest efficiency, they can in the best case, cost a lot of money and in the worst case experience a catastrophic failure.

4. Do try to visit their "bone yard" if they have one. If they really don't have one (that is, it doesn't exist, they are not just lying to you to keep you from seeing it) you are in a well maintained mill.

5. Look at the basement. With a flashlight. Look at items that should be routinely maintained. If they are a mess, the rest of the mill is as well.

6. Look at the maintenance shops. Neat, orderly? The mill might be well maintained, but be careful, there are some maintenance managers who spend all their time keeping the shop looking good, not maintaining the operating equipment.

7. Finally, look at the production records.

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Maintenance Month Bronze Sponsors:

Miami Machine: Miami Machine specializes in repairs and provides annual inspections for your reel spools, suction roll or felt rolls. Visit our website at www.miamimachine.com.

Seneca Steel Erectors: A mechanical contractor that specializes in boiler repair, conveyor repair, and custom metal fabrication. www.senecasteelerectors.com.

CBG, LLC: We can remove your nuts, bolts, studs or other fasteners quickly and get you back on schedule. cbgmaintenance.com.

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Notice what I did not have you look at? The maintenance budget. It is usually a piece of information disconnected from reality. In well maintained mills it is moderate compared to norms. In poorly maintained mills it may be very low. In mills recovering from a spate of poor maintenance, it may be extraordinarily high.

Over my years in the industry, I have found two areas where boards of directors are typically clueless. The first area is properly assessing capital project budgets. The second area is properly mandating the level or maintenance required to optimize the production of the assets as well as preserve them. Boards are loaded with people who understand the stock market, product marketing, perhaps even manufacturing, but seldom will you find a board member who has a clue about capital projects and the maintenance required to preserve and optimize assets.

For your quiz this week, we have three simple questions about "bone yards." You may take it here.

For safety this week, it goes without saying that poorly maintained assets are a source of injuries. Aha! Perhaps this is another place to look when one is assessing whether or not a mill is well maintained.

Be safe and we will talk next week.

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