(Part 3/3) The magical effect of PMC trials - a case study
A graphic paper machine in the Netherlands, Europe, initially erected in the 1960’s, was running at approximately 150% of its original design speed—causing numerous vibration issues.
The fourth press was vibration prone, resulting in a felt life of only two weeks and press roll covers lasting just four to six weeks. Even the granite counter roll showed excessive wear. Under the guise of supplier reduction, they had one supplier for all of their press felts.
After a small decade of minimal improvements (i.e. maintaining the status quo), the production manager got approval to bring in new suppliers and run PMC trials. Their goal was to achieve a life of six weeks for the fourth press felt and the roll cover lasting at least one year.
One of the new suppliers was able to achieve these goals in 18 months. After years of standstill with the original supplier, all because of the risk reduction mindset.
But there was more. Call it ‘collateral gains’ if you will. Whether it was the pressure of competition, or the more innovative mindset of the mill people, the performances of the pickup and third press felts suddenly improved too!
Around 30 months after the decision to start a continuous improvement process on press felts, the life of the fourth press felt was nine weeks (saving 17 pieces per year), they changed the maintenance shutdown cycle from once every two weeks to once every three weeks (creating 64 additional production hours per year), and the machine was running at top speed at almost all grades, saving energy due to a higher dryness at the press exit.
The actual effects on the bottomline were never exposed, but it’s safe to say that the structured and disciplined execution of felt trials, together with some healthy competition between suppliers, brought this mill millions of real money.
If you’re looking to move out of the comfort zone towards a process of continual improvement, I’d be more than happy to provide further insights and guidance.
Please do reach out to me directly at marcel.lensvelt@feltest.com.