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.

1. 1
Europe RF Update
Reisholz, Mainz, Niederbipp
Bob Drew
1 May, 2003

2. Success Stories
Reisholz
Mainz
Niederbipp

3. Reisholz Mill

4. Reisholz Mill

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

9. Pulper with new Rotor Type
Mainz and Niederbipp

10. Characteristics:
Spoiler system brings improved mixing
over total volume, especially the upper part.
Target:
Intense pulping with Reduced Pulping Time

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

13. SUCCESSFUL STORIES FROM NIEDERBIPP

14. 1. Voith Ecomizer Forward Cleaners
2. Reject Drum Sorter
3. New Pulper Rotor Design
3 Main Projects
Cost : 245‘000 USD
Savings : 323‘380 USD/Year

15. INSTALLATION OF THE
“ECO-MIZER“-CLEANER FROM
VOITH
2 % HIGHER EFFICIENCY
OF THE RF-PLANT.

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)

17. 1. Rebuilt Forward Cleaners 4th Stage
4th Stage

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

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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?

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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

24. 50
55
60
65
70
75
80
85
90
95
100
$200.00 $250.00 $300.00 $350.00 $400.00 $450.00 $500.00
Variable Cost $ US/MT
ISOBrightness(%)
RF Variable Cost Comparison

25. 50
55
60
65
70
75
80
85
90
95
100
$200.00 $250.00 $300.00 $350.00 $400.00 $450.00 $500.00
Variable Cost $ US/MT
ISOBrightness(%)
RF Variable Cost Comparison

26. R2
= 0.302
50
55
60
65
70
75
80
85
90
95
100
$200.00 $250.00 $300.00 $350.00 $400.00 $450.00 $500.00
Variable Cost $ US/MT
ISOBrightness(%)
World
Reisholz
Niederbipp
Mainz
RF Variable Cost ComparisonNiederbipp:
•Fiber Cost
•Sludge Incineration
•High Fixed Costs
Mainz & Reisholz:
•Fiber Cost
•Treatment Cost - SILAG

27. SCREENING:
•Stickies
•Contaminants
Flotation:
•Reduce Fibre
Cost
•Vs Virgin PL
Peroxide Bleaching:
•Fibre Cost at Required ISO

28. 68
Mainz Projects

29. 68
Next Steps
•More in depth cost analysis
•Quarterly Report
•Update BP Action Plan
•Project Plan 2004-2005 – Financial
Analysis

30. 68
Questions?