Manufacturing Case Study

Portuguese fully integrated manufacturer of paper

Targets to increase pulp productivity by 3-4% and paper productivity by 5%

Productivity targets for pulp and paper exceeded

A major Portuguese fully integrated manufacturer of paper covering all aspects of production from wood processing, pulp production, paper manufacture and finishing

The company had recently embarked on a major performance improvement programme with targets to increase pulp productivity by 3-4% and paper productivity by 5%
The company required a detailed analysis to establish how and where these improvements were to be generated and to identify further potential savings areas

Carried out detailed analysis of pulp operations to identify bottleneck areas, improve line balance and process stability
Carried out root cause analysis of losses in the paper mill operation
Identified and stabalized major variations in running speeds of the paper mill
Established improved management review mechanisms, communications across shift and coherent management action planning
Carried out extensive analysis (129 individual studies) of process and management data to identify further potential improvements in the following areas:
- Wood Preparation, Key Pulp Equipment Centres (Digestor, White Pulp Manufacture Finished Pulp Manufacture, Caustification Processes, Evaporators, Boilers, Chemicals Consumption, Energy Management, Provisions and Stock Control
Identified and agreed areas for further improvement with Sopocel management in Chemicals management and Energy Management
Established Action Team approach to deliver improvements

Productivity targets for pulp and paper exceeded
Additional potential annualised benefits identified, action teams for delivery set up