Domtar > Resources > Q1 2014 > Page 13
Papers many obstacles to overcome. In addition, there were some reliability issues across the mill that slowed the pace of the team’s efforts to meet the new operating targets. That didn’t stop the Marlboro team from stepping on the gas and moving full speed ahead. Within less than a week after the rebuild, the mill was producing quality paper and gaining momentum each and every day. Chris Gore, Pulp & Utilities Manager, stated, “We lost momentum after the maintenance outage, but in April it seemed like nothing could stop us.”
Headbox runnability, increased sheet width, reduced edge defects and overall sheet defects. An air turn was installed after the size press to provide gentler sheet handling. Five new dryer felt cleaning showers were installed on the unirun felts plus a ropeless threading system. To help reduce sheet defects, a new thin stock screening system was installed and improvements were made to the web inspection system and winder communication system to allow for efficient patching of defects. Over 1,500 contractors and employees were on site during this work. By the time all was done, Marlboro had experienced its busiest and longest maintenance shutdown in recent history.
GAINING SPEED Coming out of a long shutdown held in chilly January, many challenges and changes were experienced around the mill. As with any major rebuild, there is a steep learning curve and
Humidity controller core handling system
All the grade development work continued and the rebuild delivered on its promises. Appvion set production records in both April and May, surpassing their previous record that went back to 2011. Additionally, the paper machine set a record of 8 days, 6 hours and 25 minutes in November for length of time with no downtime. The old record was 6 days, 23 hours and 4 minutes set in 2009. In the midst of everything, new core handling and roll handling systems were installed. To handle the large 16” diameter 160 lb. cores required for the Appvion grades, a new “one-of-a-kind in the world” auto core handling system was put in place. In addition, the first-of-its-kind in North America roll handling system was installed to handle the 163.5” wide rolls that weigh 16,000 lbs.
DOING THE RIGHT THINGS For the Marlboro team, the transition to thermal paper grades was not the only challenge of 2013. As in every previous year, a successful journey requires doing the right things and doing them well throughout the course. Giving back to the community has always been a core value for the mill and last year was no different. Activities included a lakeshore clean-up by our EarthChoice Ambassadors, a reading program for over 4,000 school-aged children (Reach for the Highest Branch), a donation campaign for the American Cancer Society and the American Heart Association (Dump-the-Cup), proactive safety challenges for employees to benefit the local food bank and Habitat for Humanity, and a Christmas gift drive for underprivileged children. The mill also hosted a Junior/Senior tour for six local high schools and a Manufacturing Day event for community leaders. The mill also hosted the Paper Machine and Pulp Dryer Functional Team meeting as well as the Metso Annual Papermaking School. Throughout the year, over 15 mill tours were given to major customers and internal employees.
To end the year, the mill hosted Domtar’s Board of Directors and the Senior Management Committee. We gave our guests the full Marlboro experience, including a close look at the recently converted paper machine. One director was quoted as saying, “I would have paid money for that tour.”
CRITICAL LEG The most critical leg of the annual journey is ensuring employee safety. The mill strongly believes that the goal of each day is for every person to return home safely to their family. With programs and events such as Take-Two, Spot-the-Hazards, Proactive Safety Contests, Health Fairs, Risk Assessments, critical reduction techniques, safety training, sharing best practices, among others, the mill negotiated safety hurdles like never before. In July, Marlboro celebrated 365 days with no recordables. The mill was recognized in September at the annual Mill Manager’s meeting with numerous safety awards, including the inaugural Tom Detwiler Safety Pinnacle Award, given to the Domtar mill with the best overall safety performance for the year. In October, Marlboro surpassed Domtar’s and the mill’s record of consecutive days with no recordables and crossed the finish line by ending 2013 with its first ever calendar year with no recordable incidents. On December 31, the mill was at 521 days with no recordables. As Bill Edwards sums up, “I can’t say enough about the efforts of the Marlboro team in 2013. There is a lot to be proud of, but to get through all that we went through as successfully as we did without a safety recordable is something that we all can feel very good about. This only happens by having a team of folks that work well together, are dedicated professionals and come to work every day with the right attitude. Let’s keep the journey to excellence moving forward in 2014!” <
Bread of Life donation