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 Results - Turnaround of European paper mill

Context / scope of project : This paper mill was sub-scale and struggling in a market with falling prices. The Board was also interested in selling its paper division but had been unsuccessful to date. The site had tried numerous approaches to improving its operations but none had hit the bottom line and there was cynicism at all levels of the organization about the repeated calls for change and the inability of management or consultants to improve performance. The Board had seen our work at other sites in their group and brought PIP in with a brief to significantly improve profitability and create a high performing business that could sustain and improve its results further.

PIP and client achieved:

26% increase in production
   - folio up 52%
   - A4 up 38%
   - rolls up 13%

Domestic market share increases: 135% overall ($345/t benefit)

Unplanned downtime from 12 to 2.5 hrs/wk

Total broke waste reduced 50%

Effluent to drain from 0.64 to 0.24 %/ fibre

Successful sale to industry party after 15 months


   
   

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What we did:

Value Driver Trees – “Where’s the money?”
Debottlenecking
Industrial marketing (strategy, reporting, optimization tools, sales force effectiveness)
Systematic elimination of maintenance repeat failures
CPR – Critical Path Reduction for planned shuts, Shut Management & processes
Product recipe
Cost reduction – chemicals, energy, repeat maintenance failures
Raw materials optimization
Shift patterns
Reviews – morning meetings, shift handovers, weekly cascaded reviews
Sales and Operations meetings and integration
Production scheduling


 
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