The Haskell team has been focusing on how they can best support their tissue clients’ ultimate goal – to provide high quality products efficiently to the retail consumer.
While the successful tissue manufacturing companies of the past decade share many characteristics, the team found that virtually all have exercised an intentional focus on the following four initiatives:
Distribution network optimization
Minimization of downtime
In this blog, we’ll explore the last two major initiatives. Did you miss the first two initiatives? Read Part 1 first.
The tissue business has evolved into a modern, complex manufacturing industry. Worker safety is the paramount concern. It has been made a priority in both the selection of new manufacturing equipment and capital improvement projects that address the safety of existing production lines. E-stops, guarding, egress, eyewashes, fire protection, and ergonomics all must be considered to develop integrated and engineered solutions during plant upgrades and expansions.
Minimization of Downtime
It’s no secret – time is money. With that, the ultracompetitive tissue industry is demanding that production lines are installed, started-up and operated with minimal downtime. While there are countless factors that may initiate unplanned work stoppages, more tools than ever are available to ensure efficient line start-up and production continuity. Examples include:
The use of computerized simulation during line design allows for tissue manufacturers to visualize and run a new or current production process from end to end. By applying this step in the design process, simulation helps with space utilization, equipment placement, and overall production efficiency while providing the ability to address more variables without impacting cost or production. Moreover, simulation and emulation allow operators to run and debug lines in a virtual model before equipment is purchased and the line is built. As a result, modifications can be made during the design phase. Tweaking on the plant floor, and its associated downtime, is drastically reduced.
Manufacturing process design must be properly engineered. This includes allowing for adequate line accumulation. In many cases, manufacturers reduce the length of their conveyors to minimize the initial capital cost or preserve floor space, but leave little room for error. Furthermore, line speeds are maximized but do not leave an adequate timing buffer for minor back-ups. Creating the appropriate amount of space between packages and proper back-up and re-start logic allows room for minor delays and the merging products.
Integrating the design and construction of tissue making, converting, packaging, utilities, and facility improvements (or any combination of these work streams) is the dream of any tissue manufacturer’s facility improvement team. An integrated solution provider eliminates coordination errors between systems and the overall solution gets implemented in a shorter timeframe. The result: Less downtime during installation and less downtime during operation. The EPC delivery system allows for this integrated solution and is rapidly becoming the industry preferred method.
The delivery of a tissue manufacturing facility should reflect the goals of the tissue manufacturer. In today’s evolving environment, manufacturers need world-class integrated facility solutions to reduce risk, promote innovation, minimize downtime, align with business objectives and maximize collaboration.
Tissue World Americas 2014 Conference is a unique opportunity to share ideas and improve as an industry. As a participant, Haskell is proud to share site selection, master planning, engineering, procurement, and construction expertise with tissue manufacturers seeking exceptional solutions during this event.
Did you miss Part 1? Read it here. If you are attending Tissue World Americas 2014 Conference or just want to discuss how Haskell’s integrated facility solutions can help your company, please feel free to contact Haskell’s Consumer Products Division Leader, Matt Gulden, by email, firstname.lastname@example.org.