Plant Services - October 2007 - (Page 45)

ManageMent Personnel product to improve the margin. Positive cost savings began in late June and the initiative was completed in August. The broke reuse team achieved $2.2 million annual savings by reducing reprocessing shrinkage. Methods are now in place to ensure the savings are continually captured. • FMEA: The mill initiated its first ever failure modes and effects analysis (FMEA) on its 55-year-old #1 winder. Salaried and hourly production and maintenance personnel identified everything that could possibly go wrong with the winder, the severity of the problems, probability, consequences and actions to avoid future failures. As a result, a $750,000 winder replacement project was initiated in June and the installation and startup of the Webco winder was completed in mid-August. • Fiber optimization: The goal of the fiber optimization team is to enable the use of all low-cost fiber in the papers, produce more tons, increase efficiency and improve the way grades are scheduled on the paper machine. It is addressing how the departments work together to improve the quality of pulp sent to the paper machines. The team has a target of $2.1 million in annual savings from the work they will perform during their 10-week tenure. The team began in August in parallel with the paper machine reliability team because the missions are interrelated. • Paper machine reliability: The paper machine reliability team is targeting a reduction in downtime of 5% before its 10 weeks are up. Using reliabilitycentered analysis, they plan to identify and reduce the biggest causes of unscheduled downtime and capture an estimated $800,000 per year savings. Procedural changes, training and better planning of equipment outages are the primary focus. Finally, because it didn’t have the resources in house, a third-party contractor was hired to conduct condition-based maintenance (CBM) for the mill’s paper machines, pulp mill, water treatment, boiler house and turbines, and there are plans to add October 2007 Speech, Speech! ceO and majority investor Butch Johnson, flanked by Union president Dan Detko, addresses the crowd at the reopening ceremony. more equipment to the list. The mill had not had a reliability mindset for many years and management is intent on implementing processes and technologies to get it back. Management faces challenges External business challenges have required creative thinking. “Our most vicious problem is that kraft pulp hardwood and softwood prices are AMERICAN INGENUITY DISCOVER W W W.DISCOVERCURTIS.COM ©2007 Curtis-Toledo, Inc. 17639_2 07 CTGNL GENRL American.indd www.PLANTSERVICES.com 1 9/19/07 45 7:53:52 http://www.discovercurtis.com http://www.discovercurtis.com http://www.PLANTSERVICES.com

Table of Contents Feed for the Digital Edition of Plant Services - October 2007

Plant Services - October 2007 Contents Monetize It Letters Step into the Blogosphere What it Takes to be a Leader Up and Running Crisis Corner What Works From the Summit Treat Them Right Access Control Out of the Woods Show Me, Don't Guess Condition Assessment Made Easy The Air Above the Floor Power to the Prime Movers In the Trenches Illuminating Maintenance

Plant Services - October 2007

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