Greenfield Pulp Mill Ramp-Up
The fastest production ramp-up after commissioning in the pulp and paper industry. Propelance built the entire maintenance function from zero for a 1M+ ADT greenfield mega-mill in China — with an investment exceeding one billion dollars — achieving an outstanding safety record and transitioning into steady-state operations with continuous OEE improvements.
- Client
- Multinational
- Location
- 1,000,000+ ADT Annual Capacity
- Duration
- Manage engagement
- Industry
- China
- 01
A billion-dollar greenfield investment — any delay in reaching production targets directly impacted return on capital.
- 02
Commissioning delays put the mill startup under extreme pressure, with every additional day increasing financial exposure.
- 03
The required startup and maintenance know-how was limited locally — without experienced teams, commissioning quality and safety were at risk.
- 04
The maintenance inventory wasn't built up during the commissioning phase, threatening the ability to execute planned maintenance from day one.
- 01
Long-term maintenance strategy was developed from scratch to guide the organization from commissioning through steady-state operations.
- 02
The maintenance team was built through massive recruitment and training campaigns to ensure operational readiness from day one.
- 03
Maintenance and inventory management modules of the ERP system were implemented, providing real-time visibility into spare parts and work orders.
- 04
Planning and scheduling process was established to ensure structured day-to-day execution across all maintenance activities.
- 05
Shutdown management process was implemented, coordinating more than 1,000 co-workers across complex interdependent activities.
- 06
An OEE measurement system and machine criticality analysis were deployed — establishing the foundations of data-driven operations from day one.
- 07
Continuous improvement (CI) concept and tools were introduced — establishing an improvement culture from the start.
- 01
The fastest production ramp-up after commissioning in the industry — accelerating return on a billion-dollar capital investment.
- 02
Outstanding safety record compared to regional average — a critical achievement for a greenfield mega-mill.
- 03
Factory maintenance transitioned into steady operations with continuous OEE records and improvements in overall mill capacity — demonstrating that a world-class maintenance function can be built from zero.
Operational accountability across five areas.
Throughout the engagement we worked across five areas at the plant floor as part of daily operations — as operational members of the maintenance organization, not outside observers.
- 01Productivity and OEE
- 02Maintenance cost control
- 03Reliability-centered maintenance
- 04Asset condition assessment
- 05Maintenance planning and scheduling
In the industry after commissioning.
One of the world's largest pulp mills.
Involved in shutdown management.
The assumption that maintenance can be bolted on after commissioning is the most expensive mistake in greenfield projects.
Building the maintenance function in parallel with construction — not after — is what enabled the fastest ramp-up in the industry.
This principle applies to every greenfield facility: the maintenance organisation, processes, and systems must be designed and staffed before the first production line starts — not as a reactive response to the first breakdowns.
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