At one time or another, tissue converters are faced with purchasing or replacing equipment. It is a substantial investment that warrants careful consideration about how to spend capital. There is always the option to buy new, but at times it is simply a better business decision to acquire pre-owned machines.
With dangerous and disruptive log saw blade changeovers to consider, how do tissue converters keep their workers safe and their lines moving? The solution lies in the Blade Change Technical Improvement Program (TIP) — advanced automation technology that decreases human-machine interaction and significantly increases worker safety. Learn more in this video:
Manual tasks within the unwinding process put many tissue converters at a disadvantage. Operators are responsible for the preparation and transition of parent reels between paper machines and the converting line, which is physically demanding and often time-consuming. Further, these functions increase the likelihood of damage to the tissue and greatly jeopardize operator safety — all substantial risks for tissue converters.
With the advent of Industry 4.0 and smart technologies, solutions to these challenges are now available and Fabio Perini’s new Moonlight unwinder virtually eliminates off-line human intervention during unwinding through forward-thinking automation:
Fabio Perini North America has always focused on adding value as a full-service partner for tissue converters. So, when the opportunity arose to eliminate waste, improve quality and deepen customer relationships through the implementation of Lean practices, the choice was easy. Learn more in this video.
As tissue converting equipment advances, a customer’s knowledge may not keep pace, which can lead to a disconnect when trying to solve problems or improve efficiencies. Fortunately, skilled technicians are available via augmented reality to help troubleshoot problems digitally. Learn more in this video.
Like any industry predicated on production, tissue manufacturing and converting presents a certain amount of peril to workers. The amount of equipment and humans on a production floor alone can make for hazardous situations, not to mention the often heavy, sharp, and quickly moving parts within that equipment that workers must be cognizant of at all times to prevent injury if safe practices and machine safety procedures are not being followed or used.
A measure of the difference between the ideal — the cost of doing everything perfectly the first time every time — and the actual costs associated with the reality of errors and inefficiencies in processes, the Cost of Poor Quality (COPQ) can erode as much as 15-20% in sales revenue and up to 40% of total operational budgets for many organizations. If resolving quality issues isn’t addressed until somewhere in the cycle when the product transitions from planning to manufacturing to distribution, COPQ could further endanger profitability.
Parts obsolescence presents ongoing challenges and inherent risks within a number of industries, including tissue converting. Minimizing the threats posed by obsolete parts is both imperative and possible provided you identify the causes, understand the consequences and proactively find solutions.
Today’s tissue converters are serving customers who expect fast turnarounds and minimal downtime. Finding ways to be more cost-effective, efficient and focused on production is a top priority.
A new tissue converting line holds a lot of promise for your business — process efficiencies, product improvement, potentially higher profits. Fulfilling that promise requires a successful tissue converting line setup, which can be easier said than done without proper preparation.
Being aware of what might go wrong and how to avoid common pitfalls will save time, alleviate possibly costly delays and ensure the tissue converting line setup goes smoothly.