1. Summer 2016: Final
Presentation
Alden Anderson
Technical Summer Intern
8/8/2016

2. SAFETY Projects
• As part of a follow-up for PM2 felt side coating
filter safety issue investigated possible causes
for resin build-up on PM2 filters
• Performed the Annual DOLPHIN chemical
audit for Material Prep and QA

3. Resin Build-up on PM2
• Investigated build-
up of resin on PM2
filter as a response
to recent back
injury
• Collected samples
of sub coat daily to
take readings on pH
and viscosity in
order to create a
base line data

4. Resin Build-up on PM2
• Created updating graphs that show pH and
viscosity over time
0
100
200
300
400
500
600
700
800
900
1000
5/30/2016 6/9/2016 6/19/2016 6/29/2016 7/9/2016 7/19/2016 7/29/2016 8/8/2016
Viscosity(cP)
Date
Loop Coating Viscosity
*Samples from PM2 Feltside Tank
*Red means build-up was
seen

5. Resin Build-up on PM2
5
5.5
6
6.5
7
7.5
8
8.5
5/30/2016 6/9/2016 6/19/2016 6/29/2016 7/9/2016 7/19/2016 7/29/2016 8/8/2016
pH
Date
Loop Coating pH
*Red means build-up was seen
*Samples from PM2 Feltside Tank

6. Resin Build-up on PM2
• Collected samples of sub-coat and resin on
day when there was build-up and sent to
Appleton for testing
FS Loop Sub-Coat Resin Build-Up Sample FS Return Sub-Coat

7. Dolphin Chemical Audit
• Investigated list of chemicals in question to
see if they were still used
• Initially 83 chemicals were unknown in
Material Prep and 11 were unknown in QA

8. Dolphin Chemical Audit
• After the investigation was complete, Matt and I had
ascertained information on all of the chemicals in
QA and 64 of the chemicals on the Material Prep list.
• List was then sent to Johnna Fries so chemicals could
be updated in DOLPHIN with SDSs or archived

9. QUALITY Projects
• Lead Kaizen to reduce/eliminate Roll
Mislabeling Complaints and Non-
Conformances
• Developed a Roll Quality Vertical Audit
Process
• Helped with Development of a Finished Roll
Quality/Splice Audit
• Worked to loosen the 20% Curl Reject Limit
for MM 4781 on PM3 and PM2

10. Kaizen for Stamping/Labeling
• Learned what a Kaizen
entailed from the CI
Department
• Investigated Non-
Conformances from the
last year about stamping
and labeling
• Learned how incredibly
valuable operator input
was as they helped
identify problems I would
have never seen

11. Kaizen for Stamping/Labeling
• At the Kaizen the root causes of the
Stamping/Labeling issue were identified
• Created a list of countermeasures to
reduce/eliminate the issue
– These included roll audits, creating SOP for roll
labeling, applying all CB roll labels at Head roll
station, informing operators on customer
complaints and NCs, and highlighting roll position
on belly tags
– Weekly meetings to monitor progress

12. Roll Quality Vertical Audit
• Creation of the Roll
Quality Vertical Audit
began with the idea of
raising awareness about
our current specs
• Then the major issues
were identified in order
to create an audit sheet

13. Roll Quality Vertical Audit
• Implementation of the
Audit involved
numerous trials and
modifications
• Creation of a record
system in order to
monitor progress of
the audit
• Carrying out the audits
themselves

14. Finished Roll Quality Audit
• This audit stemmed from a desire to inspect
splices
• Doug Guise’s old audit was found and
modified to meet new specs
• Audit is currently being trialed

15. Loosen 20% Curl Reject Limit on MM 4781
• Particular grades on
PM3 are seeing a
problem where in order
to get the 50% humidity
curl test to Target the
20% curl is being run in
pre-control
• Decided to focus on
MM 4781 for proposing
the change

16. Loosening 20% Curl Reject Limit
• Pulled data from June
2015 to present to
investigate where
exactly changes need
to be made
• Using histograms
created a proposal for
creating new lower
limits

17. Loosening 20% Curl Reject Limit
• Proposed new 20%
curl lower limits for
MM 4781
• Put in a formal
request for a spec
change

18. Other QUALITY Projects
• Helped monitor 20# Cream Bond to ensure it met
quality requirements
• Established collaborative testing program for
kCoF tester
• Looked into trends for the difference between
the 2 minute and 30 second TI
• Improved TSGs for the QA laboratory equipment
• Created defect books for each Paper Machine and
QA Lab

19. 20# Cream Bond Quality
• Helped investigated complaints by C&J to
determine predicament
• Watched 20# Cream Bond run and inspected
splices during run

20. kCoF Testing Program
• Created to prevent
kCoF test from drifting
• Contacted Ellen
Roberts and involved
Appleton it testing
• Created sheet to
record and compare
test values from both
facilities
• Status-Starting this
month

21. 2 Minute VS. 30 Second TI to Monitor Print
Speed
• Investigated benefit of a graph of the
difference between 2 minute and 30 second TI
• Decided difference graph was redundant if we
have 30 second and 2 minute graphs already
-20
-15
-10
-5
0
5
10
15
18-Sep-14 00:00 27-Dec-14 00:00 06-Apr-15 00:00 15-Jul-15 00:00 23-Oct-15 00:00 31-Jan-16 00:00 10-May-16 00:00 18-Aug-16 00:00
Difference for CB TI: 2 Min Minus 30 Sec

22. Improved TSGs for QA Lab
• Improved TSGs for
– Contact Angle Test
– Ink Penetration Size Test
– Mullen Burst Strength Test
– Stiffness Test
– Caliper Test
– kCoF Test
– Color Touch Test
– Scott Internal Bond Test

23. Defect Books
• Located any remaining defect books
• Filled Defect Books with defect sheets and put
them in proper locations for future use

24. What I Learned
• The importance of Safety
• The value of feedback
• The benefits associated with teamwork
• A understanding of what it is like to work in an
industrial environment