What's Happening?
Domtar's Johnsonburg Mill in Pennsylvania has launched an in-house training program, Precision Maintenance on Demand (PMoD), to enhance maintenance skills and improve equipment reliability. This initiative also aims to preserve technical expertise as experienced
employees retire and new workers join the maintenance workforce. The PMoD program moves beyond reactive repairs, focusing on proper installation, alignment, and maintenance practices to ensure machinery operates reliably throughout its service life. Developed with input from reliability specialist Dan Morgan and maintenance supervisor Bryce Barclay, the program includes 26 learning modules, approximately 30 hours of video content, and practical exercises delivered through a five-day course. Participants engage in hands-on training covering proper torque and lubrication procedures, soft-foot correction, and laser alignment. They also learn to measure and analyze vibration, temperature, amperage, rotational speed, and noise on equipment with known faults, helping them identify potential signs of failure and evaluate corrective adjustments. This approach emphasizes understanding factors affecting equipment reliability rather than solely focusing on post-breakdown repairs.
Why It's Important?
This in-house training program is crucial for Domtar's Johnsonburg Mill as it directly addresses a significant workforce challenge: the loss of experienced maintenance employees. Since 2024, 44 maintenance employees have retired or left the mill, which has 83 hourly maintenance employees when fully staffed. By relying on experienced employees as instructors, Domtar is establishing a structured method for transferring critical technical knowledge to a new generation of mechanics, thereby preserving institutional expertise. The tailored instruction, specific to the mill's equipment and operating conditions, is expected to lead to more effective maintenance practices compared to generic external training. Improved equipment reliability can reduce unplanned downtime, increase operational efficiency, and potentially lower maintenance costs, contributing to the mill's overall profitability and competitiveness in the paper industry. This proactive approach to workforce development and asset management is vital for sustaining long-term operational stability and productivity.
What's Next?
The PMoD program is an ongoing component of Johnsonburg Mill's broader reliability strategy. While Domtar has not yet provided quantified results on equipment reliability improvements or reductions in unplanned downtime, the continuous implementation of this training is expected to yield long-term benefits. The mill will likely continue to integrate technical skill development with practical maintenance expertise transfer. Future steps may involve expanding the program to cover more specialized areas, updating modules based on new equipment or technologies, and potentially sharing best practices with other Domtar facilities. The success of this program could also influence recruitment strategies, highlighting the company's commitment to employee development and creating a more skilled and resilient workforce. Ongoing evaluation of equipment performance metrics will be essential to measure the program's effectiveness and make necessary adjustments to optimize its impact on operational reliability.
Beyond the Headlines
The implementation of Domtar's PMoD program at the Johnsonburg Mill highlights a broader trend in U.S. manufacturing: the critical need for internal knowledge transfer and skill development in the face of an aging workforce. Many industries are grappling with the retirement of highly skilled, experienced employees, leading to a potential 'brain drain' of invaluable technical expertise. By creating an in-house program that leverages the knowledge of seasoned workers, Domtar is not only addressing immediate maintenance needs but also fostering a culture of continuous learning and mentorship. This approach can enhance employee engagement, as experienced workers feel valued for their contributions as instructors, and newer employees gain practical, context-specific skills. Furthermore, investing in precision maintenance shifts the operational paradigm from reactive repairs to proactive asset management, which can lead to greater sustainability, reduced waste, and a more resilient industrial infrastructure across the nation. This model could serve as a blueprint for other U.S. companies facing similar demographic and skill-gap challenges.
