validus management consultancy UK

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

THE ORGANISATION

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

THE ISSUES / PROBLEMS

  • 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

PROJECT ACTIVITIES

  • 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

PROJECT RESULTS

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