Case Studies

Improving uptime in Packaging and Paper Processes

Over recent years System 21 has built up niche expertise in the paper and packaging industry. Our clients include Kimberly-Clark, KNP paper mills, the Waddington group, Macfarlane Group plc and other printing and board manufacturers.

The paper industry is special in that the vast overhead costs of plant and machinery far outweigh the variable costs of production. The production process is most efficient when it is able to run uninterrupted at the optimum throughput rates for the machine. However, this is rarely possible due to grade changes in paper production and set ups in the printing industry. Cost efficiency therefore relies on the effectiveness of the supply chain.

Information and preparation of materials are critical as is the scheduling of set ups and change overs from one product or specification to another.

The System 21 approach is not limited to production processes. Our Project Teams have achieved substantial improvements in production "uptime" by focusing on the entire process from sales order entry, through materials planning, production and finishing. System 21 projects have considerably improved maintenance planning controls and rapid response times to breakdowns or web breaks. Typical uptime improvements in excess of 10% are now being recorded by operations that were already efficient. Organisation restructure is the route to more effective front end communications and there are often cost savings as well as a reduction in delays and communication errors. Substantial scrap and rework savings can be achieved subject to product specification and the technology available. Interestingly, all projects required existing computer systems to be explained better to users in order to capitalise on their full capabilities.

 

 

 

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