Tissue360 - Spring/Summer 2018 - 19

Scappoose Achieves Zero
Incident Rate
Anyone who has worked in manufacturing has heard the old saying, "Safety doesn't happen
by accident." It requires management commitment, employee engagement, tested rules and
protocols-in short, a lot of work. Yet for those outside the plant, a good safety record isn't
an achievement, it's an expectation, and they're only likely to notice when things seem less
than perfect.
At Scappoose, management and operators take the opposite approach: they celebrate the
facility's stellar safety record, and have created a culture where safety is a top priority. The
facility achieved a zero incident rate during the 13-month construction phase, and as of press
time has maintained the record for 410 days.
"As proud as we are of what has been created here, we are equally proud of our safety performance," Mill Manager Joe Ertolacci told visitors, local dignitaries, and members of the press
at the facility's July inauguration ceremony. "We take safety very seriously at Cascades, and
at the Scappoose converting facility."

Master tech Doug Keizur speaks to a tour group at

the inauguration event.
Ertolacci says that, from the beginning, employee involvement has been the key to this success.
"We did our best to set a vision where nobody was ever injured and where we're all responsible
for each other. This mentality led us to develop some great initiatives-such as 'stretch and flex' sessions where employees take part in
light morning workouts together. We then perform safety observations on each other in an environment of caring for each other. It helps
people to prepare for a working day, keeps them fit and focused on safety. Our motto is 'Tomorrow is your reward for working safely today.'"

The enthusiasm for safety is evident on the plant floor as well-and the local media has noticed. A recent article in the St. Helens Chronicle
quotes Doug Keizur, master tech at Cascades Scappoose facility: "While his machine runs quietly in the background, he explains the
rigorous safety regime. 'We review safety operations on a weekly basis,' he explains. He is obviously proud of the plant's 279 safe days."

world-class record for changing rolls on
that line was three minutes. Our operators
achieved 1:55. They beat the record from the
supplier multiple times. When I was doing
the inauguration tour the operators were all
there, and you can see the pride on their faces.
That was amazing."
Plans for expanding the Scappoose facility
have been in place since the beginning. The
second phase of the project will add three
additional converting lines, plus a fully automated warehouse behind the existing facility.

"You have to reduce your risk as a company, so that's what we did," says Jobin. "For
instance, right now on Line 1, we make multiple products. That's not ideal, but we have
two emboss stations. When we do Phase 2,
we'll move one of the emboss stations there,
to simplify the process of both lines."
The time frame for building and starting up Phase 2 will depend on how quickly
Cascades can push the new capacity into
the market. According to Plourde, when the
Scappoose plant is running at 80 percent

President and COO Jean Jobin speaks
at the Scappoose converting plant's
inauguration ceremony.

Oregon Governor Kate Brown spoke at the
facility's inauguration.

capacity and trending upwards, Phase 2 will
begin. "I think we made the right strategic
decision to come here to the West Coast and
establish a facility close to our mill," he says.
"I think we chose the right people. I hope the
community accepts our product and we'll be
able to expand soon-that's our goal."
STAFFING UP
The plant will create 80 permanent jobs (it
also created 200 jobs during construction).
Typical operator pay ranges between US$2038 an hour. Cascades also offers a lucrative
benefit package, including above-standard
health care and a 401k match and profit sharing plan. This was key to securing the local
incentives. "These are substantially higher
wages than the average in Columbia County,
so we're very pleased," commented Oregon
State Senator Betsy Johnson, who spoke at
the inauguration ceremony.
Plourde notes that creating the "Cascades
culture" was important. "When we engaged
the employees, before the mill was built, we
started by talking about our values-what
we expect from them as employees, how we
expect them to work in the facility and collaborate with their partners. We're trying to
'responsibilize' the employee. If you need a
supervisor to supervise an employee to do
Tissue360º SPRING/SUMMER 2018

19



Table of Contents for the Digital Edition of Tissue360 - Spring/Summer 2018

Setpoint
Tissue Industry News
Welcome to Scappoose
Meeting the Challenge of e-Commerce
Tissue 2018 Comes to Appleton
Ensuring Rolls Run Right
Streamlining the Parent Roll Supply Chain
Gomà-Camps Creates an Edge, Again and Again
iT’s Tissue 2018 Set to Roll
Tissue360 - Spring/Summer 2018 - Intro
Tissue360 - Spring/Summer 2018 - cover1
Tissue360 - Spring/Summer 2018 - cover2
Tissue360 - Spring/Summer 2018 - 3
Tissue360 - Spring/Summer 2018 - 4
Tissue360 - Spring/Summer 2018 - 5
Tissue360 - Spring/Summer 2018 - Setpoint
Tissue360 - Spring/Summer 2018 - 7
Tissue360 - Spring/Summer 2018 - 8
Tissue360 - Spring/Summer 2018 - Tissue Industry News
Tissue360 - Spring/Summer 2018 - 10
Tissue360 - Spring/Summer 2018 - 11
Tissue360 - Spring/Summer 2018 - 12
Tissue360 - Spring/Summer 2018 - 13
Tissue360 - Spring/Summer 2018 - 14
Tissue360 - Spring/Summer 2018 - Welcome to Scappoose
Tissue360 - Spring/Summer 2018 - 16
Tissue360 - Spring/Summer 2018 - 17
Tissue360 - Spring/Summer 2018 - 18
Tissue360 - Spring/Summer 2018 - 19
Tissue360 - Spring/Summer 2018 - 20
Tissue360 - Spring/Summer 2018 - 21
Tissue360 - Spring/Summer 2018 - 22
Tissue360 - Spring/Summer 2018 - Meeting the Challenge of e-Commerce
Tissue360 - Spring/Summer 2018 - 24
Tissue360 - Spring/Summer 2018 - 25
Tissue360 - Spring/Summer 2018 - 26
Tissue360 - Spring/Summer 2018 - 27
Tissue360 - Spring/Summer 2018 - Tissue 2018 Comes to Appleton
Tissue360 - Spring/Summer 2018 - 29
Tissue360 - Spring/Summer 2018 - 30
Tissue360 - Spring/Summer 2018 - Ensuring Rolls Run Right
Tissue360 - Spring/Summer 2018 - 32
Tissue360 - Spring/Summer 2018 - 33
Tissue360 - Spring/Summer 2018 - 34
Tissue360 - Spring/Summer 2018 - Streamlining the Parent Roll Supply Chain
Tissue360 - Spring/Summer 2018 - 36
Tissue360 - Spring/Summer 2018 - 37
Tissue360 - Spring/Summer 2018 - 38
Tissue360 - Spring/Summer 2018 - Gomà-Camps Creates an Edge, Again and Again
Tissue360 - Spring/Summer 2018 - 40
Tissue360 - Spring/Summer 2018 - 41
Tissue360 - Spring/Summer 2018 - 42
Tissue360 - Spring/Summer 2018 - iT’s Tissue 2018 Set to Roll
Tissue360 - Spring/Summer 2018 - 44
Tissue360 - Spring/Summer 2018 - 45
Tissue360 - Spring/Summer 2018 - 46
Tissue360 - Spring/Summer 2018 - 47
Tissue360 - Spring/Summer 2018 - 48
Tissue360 - Spring/Summer 2018 - 49
Tissue360 - Spring/Summer 2018 - 50
Tissue360 - Spring/Summer 2018 - cover3
Tissue360 - Spring/Summer 2018 - cover4
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