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Forest Products and Paper Industry:
Manufacturing Process Improvement/Product
Quality Improvement/Cost Reduction
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Client: |
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A major American
paper company specializing in the manufacture of non-woven papers
and paper products.
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Problem: |
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Need to improve
product uniformity and consistency and reduce manufacturing costs
to satisfy increasing market requirements for high performing products.
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Approach: |
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Using a variety
of methodologies including basic statistical techniques (Process Control
and Capability), advanced statistical techniques (Experimental Design
- DoE), and Six Sigma (DMAIC) problem solving techniques to study
the paper manufacturer’s supply chain, pulping, digestion, paper forming,
drying, and finishing processes, the critical paper product characteristics
were quantified and sources of product and process variation were
identified. The relationship of key process variables to product characteristics
and process performance was established along with the determination
of improvement opportunities to reduce product variation, improve
manufacturing consistency, and reduce scrap and rework costs.
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Results:
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Dramatically
improved process and product quality including a 70% reduction in
product variation, a 25% reduction in quality defects, and an 80%
reduction in costs associated with product scrap and rework. Cross-machine
and machine-direction paper profiles for key paper quality characteristics
were significantly improved (flattened and optimized) while optimizing
process performance and minimizing out-of-specification performance
and variability. Within “campaign” and between “campaign” variability
was notably reduced and ease of manufacture was greatly improved.
Sample and quality control test requirements were reduced to reflect
improvements in process control and product quality. Customer satisfaction
was favorably impacted and the manufacturer became a preferred supplier
for critical product end-use applications. The learnings and resulting
processes developed for these specialty papers became a model for
improving other products and processes. |
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