World Class en el mundo industrial es sinónimo de excelencia; el concepto World Class Manufacturing (literalmente «Fabricación industrial de nivel mundialmente reconocido») significa de primera división, es la manera de fabricar algo que los demás fabricantes quieren imitar. Recoge estrategias como el Control Total de la Calidad (TQC), el Método justo a tiempo (JIT), el Mantenimiento Productivo Total (TPM) y otras estrategias de gestión, tecnología y servicios.
World Class Manufacturing significa ser competitivo en la fabricación industrial a nivel de los mejores en todo el mundo; no es solamente una extensión de TPM. Al contrario: es una herramienta para conseguir estar entre los mejores a nivel mundial (World Class Manufacturing).
WCM puede considerarse una ampliación del TPM (Total Productive Maintenance or Management). A los 4 pilares básicos de TPM que son, a saber: mejora focalizada, mantenimiento autónomo, mantenimiento profesional y mantenimiento en la concepción, se han unido otros pilares, que son: seguridad, higiene y ambiente en el trabajo, medio ambiente, servicio al cliente, control total de la calidad del producto, desarrollo del personal y reducción de costes. Esto da una idea del nuevo modelo industrial, que se enfoca directamente al cliente. Las factorías, desde lo más básico hasta lo más avanzado en sus procesos, procuran alcanzar la total satisfacción del cliente.
5. Wet Strength Efficiency with RF
Grade Towels
• Reduced from 6 lpm to 3 lpm on RF Towels (80 kg/MT
to 40 kg/MT)
• Solution – Switch from 1000 m³/h long whitewater
loop to short white water loop to retain Kymene in
short loop with fibre. On normal production, the Silag
used all white water of the paper machine (400
m³/h) building and all from RF plant (600 m³/h)
• To shorten loop on RF towels, we used our Krofta for
clarification and not the outside Silag flotation. So
now white water goes from the PM building direct to
the Krofta. Clarified water is recycled to the paper
machine.
6. The old “Single“ Water Loop
RF Plant 600 m³/h from DNT‘s
TM Building 400m³/h from Tray Chest Silag 1000m³/h
7. The new “Double“ Water Loop
RF Plant 600 m³/h Silag 600 m³/h
TM Building 400m³/h
Krofta Flotation
11. Results:
Dilution time reduced from 15 min to 10 min.
Dilution time/t and pulper energy
consumption/t reduced by about 10 %.
Increased fiber yield
Less reject and disposal costs
Increased pulper system capacity
Results will be quantified over
a longer time period.
12. Niederbipp Results New Pulper-Rotor
Cost : $37 k
Savings : $80 K/Year
+ 0.8 Ton / Day Increased Throughput (6
% Improvement)
+ Can Pulp Longer Fibre Length
16. 1. Rebuilt Foward Cleaners
Cost: $97 K
Savings: $180 K/Year
+ 1.7 MT/Day Reduced Fibre Loss
+ Reduced Ash
1. Cleaner Stage 1 Remains Stages 2,
3, and 4 Rebuilt to Ecomizer
2. New Dilution Water Pump for Stages
2 and 3
3. Reduction Number of Pipes
Stage 2 from 28 to 20
Stufe 3 from 8 to 4
Stufe 4 from 4 to 1
4. Less Instrumentation at Stage 4:
(Removed some valves, no
compressed air necessary)
Stages 1 to 3, Stufe 1 im Vordergrund
(APA Bedienungsboden)
18. HIGH PRESSURE NEEDLE SHOWER
IN REJECT SCREENING DRUM
FIBRE FREE REJECT
AFTER DRUM
19. 2. Reject Drum Sorter HP Shower
Kosten : $93 K
Einsparung : $103 k/Year
1. Took off oscillator and Drum not
Changed
2. Needle Jet Nozzles Installed
3. New 40 Bar Pump
4. Same Experience in Other Mills in
Switzerland
5. Reduced Cleaning Frequency
Sortiertrommel nach erfolgreichem
Umbau in Utzenstorf
20. 2. Reinigung Sortiertrommel auf 40 bar erhöhen
Nadelstrahldüsen
40bar
Düsenstücke neu und
näher an der Trommel
21. + 1.2 Tons/ Day Fiber Recovery
+ Less Plugs and Cleaning Time for Operator due to More efficient
Drum Cleaning
+ Less Ash
- Install additional HP Pump to Reach 40 Bar
2. Reject Drum Cleaning Shower at 40 bar
22. 68
FCE Europe RF Optimisation
• Demand for Higher Brightness – PL Customers
Demanding Virgin Fibre
• Price Differential RF and Virgin fibre low – In
Short Term
• Cost Challenges in Germany
• Fiber Quality Opportunities
What is RF Strategy for FC
Europe?
23. 68
Approach to RF Optimisation
Action Plan &
Analysis
RF Process
Database
Implement
Plan
Cost
Comparison
•Within FCE
•Global
•Identify Opportunities
•Financial Analysis – Equipment Plan
•Best Practice Opportunities
•Fibre, Utilities, and Chemical Opportunities
•Capital Plan 2004
•BP Action Plan
•Long Term Fibre Strategy
•Key Comparisons – Equipment and Fibre Quality
•Identify Gaps & Opportunities