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THE COMPANY A tissue manufacturing, and finishing operation employing approximately 60 people producing a single bathroom tissue product, one of the top ten brand names in the UK. THE CHALLENGE To increase the volume output form a continuous process operation whilst maintaining quality. The process end to end includes a five-meter tissue mill, two high speed tissue winders and associated packing equipment.
THE STRATEGY A simple manufacturing equation was the focus of our strategy Process Capability x Asset Utilisation = Productivity By identifying the key process variables and implementing an appropriate measurement system we were able gain a much higher level of process control leading us towards reduced waste in the mill and higher levels of process predictability. A more predictable product from the mill resulted in increased speed and reduced waste at the winders. By implementing an asset utilisation monitor we were able to understand the major causes of down time and so to increase productive up time at the mill, the winders and the packing equipment. THE BENEFITS Over a period of eight months
QUOTES FROM THE MANAGEMENT "This is such a big process with so many variables it’s difficult to stay in control…For the first time in three years I feel confident we will meet our production targets." Operations Leader "Measurement means being able to deal with what actually happened rather than what someone thinks happened. By reviewing the performance of the mill on a daily basis we are in much better position to maintain control." Mill Process Engineer Addendum Six months after the completion of the programme, the process continues to break records. Over this period case output has risen by a further 8% |
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