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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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