Lean Kaizen in Paper Manufacturing

• Map the full value stream: stock prep → approach flow → paper machine → coating/calendering → winding → finishing → dispatch.
• Identify true bottlenecks (wire/press/dryer section, coater, winder, sheeter) and rebalance upstream/downstream capacities.
• Reduce unnecessary intermediate handling and queueing of reels and pallets through flow-based layouts and WIP limits.

• Calculate OEE for the paper machine and key finishing equipment, breaking losses into speed, downtime and quality.
• Use structured data and Pareto analysis to attack top causes of sheet breaks, slowdowns and unplanned stops.
• Optimisation of Planned shutdown loss using SMED principles and reliability maintenance
• Apply SMED principles to grade and deckle changes – standardising sequences, pre-setting recipes and minimising on-machine adjustments.

This results in higher sustainable machine speed, fewer breaks and more saleable tonnage from existing assets.

• Analyse mass balance and yield from pulp preparation to finished reels, including broke returns, trim, coating loss and off-spec reels.
• Standardise centreline process conditions (consistency, refining, basis weight, moisture, temperature, chemistry) and make deviations visible on the shopfloor.
• Run focused kaizens on broke generation points (wet end breaks, edge cracks, winder breaks) and trim optimisation in sheeting.

This results in higher saleable yield per ton of fibre and fewer downgraded or scrapped reels.

• Treat energy and water as “hidden raw materials” and map usage by process and equipment.
• Improve steam and condensate systems, hood ventilation, vacuum systems and compressed air through leakage elimination, better controls and right-sizing.
• Optimise pumping systems and water circuits, reducing recirculation and unnecessary flows.

This results in lower specific energy and water consumption per ton, and more stable process conditions.

• Define critical-to-quality parameters for target markets (basis weight, moisture, strength, gloss, smoothness, opacity, printability, stiffness).
• Shift from “inspect at the end” to in-process control with clear reaction plans when trends move towards out-of-spec.
• Use QC Story problem solving on recurrent complaints (dusting, mottling, curl, coating defects, reel geometry issues).

This results in higher first-time-right rate, fewer returns and stronger brand reputation with converters and printers.