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    Pulp and Paper Industry - SIX SIGMA

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    Pulp and Paper Industry - SIX SIGMA

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    Six Sigma Tool Application in Pulp and paper industry

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    Six Sigma Tool Application in Pulp and paper industry

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    © All Rights Reserved
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    Download as pdf or txt
    100 views1 page

    Pulp and Paper Industry - SIX SIGMA

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    Project. Work
    Six Sigma Tool Application in Pulp and paper industry

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    of 1

    SNAPSHOTS OF SUCCESS

    Pulp and Paper Industry


    Case Studies
    DELIVERING OPERATIONAL EXCELLENCE Six Sigma Qualtec

    The cost of poor quality can represent 20% to 30% of a company’s total revenues. The following case
    studies demonstrate how Six Sigma Qualtec helped its client achieve breakthrough performance,
    captures cost savings and increases customer satisfaction.

    Straight-line Gluer Efficiency Recovery Boiler


    At a carton-producing facility, the straight-line gluer in Throughput Report
    use was producing at a rate of 33% below its capacity. Within the recovery department of a major pulp producer,
    The improvement targeted was a 50% increase in Net operation inefficiencies were found within the two boil-
    Efficiency Output (NEO), which would save an estimated ers used to convert black liquor into green and then
    $250,000 annually. Based on extensive statistical and white liquor. The process was mapped and Six Sigma
    Pareto analysis, it was decided to target downtime and methodology was applied, providing the company with
    spoilage specifically. There was a strong focus on standard operating procedures to measure liquor solids
    mechanical fixes and developing and conducting exten- consistently while giving operators a clear view into how
    sive operator training. The completed project exceeded the system is performing. This new streamlined operation
    the original goals by 11%, with final results of a 50% removed a chronic bottleneck in the production of green
    reduction in downtime and a 40% decrease in spoilage. liquor, resulting in annualized savings of $226,000.
    This increased Net Efficiency Output by 61%, with Based on the new measurement system installed for
    savings of $316,434 from this project. To maintain primary metrics, operators are also able to make
    this new output, control plans were put in place with refining changes on the control limits, thus decreasing
    preventative maintenance schedules and new hire standard deviation between the concentrators.
    and refresher training programs.
    Paperboard Waste Reduction
    Turn-up Loss Sheet-Fed Process
    Within a leading paperboard company, a project goal
    Within the sheet/print/cut process of a leading paper-
    was set to reduce turn-up loss. Turn-up loss data was
    board company, a project goal was set to decrease waste
    collected to quantify the opportunities for improvement,
    to 6.5% from the current 7.6% historical baseline
    including spool loss, lap loss, winder process loss, and
    average, resulting in an annual cost savings of
    © 2006, Six Sigma Qualtec. All rights reserved.

    quality sample loss as well as to minimize customer


    $120,000 based on the same level of production. By
    complaints from turn-up tape marks, wrinkles, and core
    reusing waste sheets, improving reporting procedures
    marks. The objective was to reduce the current average
    and developing a set of “best practices/procedures,”
    of 1.01 percent to .90 percent. Six Sigma tools were
    the team was able to obtain a monthly average waste
    applied to target problem areas. By improving reporting
    of 4%, resulting in an annualized savings of $696,000
    procedures, the team was able to obtain a .922 percent
    (assuming the waste would otherwise have remained at
    turn-up loss with an annualized savings of $89,000.
    the 7.6% average). Additionally, it was recommended to
    continue the improvements in waste reduction and
    expand beyond the sheet/print/cut process.

    toll free 800.247.9871 phone 609.925.9458 email [email protected] www.ssqi.com

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