Lean Six Sigma in Forestry & Paper Industry
As per the industry classification benchmark, this industry sector includes the following subsectors –
Forestry – Owners and operators of timber tracts, forest tree nurseries and sawmills. Excludes providers of finished wood products such as wooden beams, which are classified under Building Materials & Fixtures.
Paper – Producers, converters, merchants and distributors of all grades of paper.
Applications in paper industry
The paper industry is exposed to challenges like increased demands for customized products, customer delivery times and changes in customer schedules. All this has lead to an increased pressure on the prices as well as the margins. Over the years the paper industry is faced with the problem of high energy costs with a lot of energy getting consumed in drying the paper. Six Sigma tools like DOE have been used to reduce the energy costs by identifying, optimizing and controlling the input variables like temperature of the heaters, speed of the fan and the distance of the fan from the paper. Once the best combination of Input variables is attained energy costs can be reduced. Some other examples of Lean Six Sigma application in Paper Industry are:
- Improving the paper machine efficiency
- Ensuring timely availability of raw material by improving underlying processes
- Reducing cost of production
- Minimizing waste and scrap
- Improving the overall quality of production
Case Study Description
A paper manufacturing company found that defect rate was affecting margins and repeat orders. The common reasons for rejection were found to be Low Brightness, Dull Shade, Poor Opacity, Gsm Variation, Static Charge, Low Strength, Poor Sizing, Specks, Low Bulk, Shade Variation, poor smoothness, and poor formation.
Drilling the issues for top contributors of rejection to process level, it was found that there were many factors that affected the brightness, namely – Raw material category, pulp temperature, pH of pulp after paper mixer, temperature of pulp after heater mixer, hypo GPL, pH of pulp in tower, reaction time in tower, pH of pulp in potcher washer, degree of washing, pH of pulp in stock chest, starch GPL, pH of starch after size press, ash %.
DoE was used to find the critical inputs that needed better controls. After making changes as suggested by analysis of experimental results, it was time to create a good control plan. Through FMEA, it was found that failures in raw material section, high consistency pulper, machine chest, size press had the highest Risk Priority Numbers. Control mechanisms were devised and implemented to finally solve and close the problem.
Feedback from participants
I liked the practical examples and introduction to various tools to be used for the Green Belt operations.
– Abhishek Kapoor, Business Executive, Tolaram Group, Nigeria.
A great course highly beneficial for understanding today’s business.
– Karishma Kamboj, Tolaram Group, Nigeria.
Six Sigma is a good process & should be used by Companies for increasing their efficiency in all areas.
– Madhukar Khetan, General Manager- Finance, Tolaram Group, Nigeria.
Very logical and easy to understand. Very relevant to apply in any sector / department.
– Divya Rathi, It Head, Tolaram Group, Nigeria.
Every business that is success driven should abide in sigma concept, for their business growth and customer satisfaction.
– Camillus Udeabanihu, QC Manager, Tolaram Group, Nigeria.
A great facilitator well prepared course and simple real practice example to provide quick understanding to Six Sigma.
– Eric Samalo, Treasury Head, Tolaram Group, Nigeria.
The Green Belt training was very structured and interesting.
– Gaganjit Kahlon, Head ERP, Tolaram Group, Nigeria.
Very good tool to use in the organization & also in daily life to reduce defect and improve yield.
– Kaushik Barman, Operations Manager, Tolaram Group, Nigeria.
Great tool for problem solving, whether it is business or life. Kudos to benchmark six sigma.
– Abhishek Mohunta, Marketing – Creatives, Tolaram Group, Nigeria.