|
|
Writer for Nip Impressions
Thursday, September 29, 2022 1:01 pm
Quality starts at home, and that home is often your home, your car, and your workspace. Organization exudes quality. Ever walked into an automobile dealership? Was it disheveled or spotless? How would you react if you walked into an automobile dealership that was untidy? If we are going to talk about quality, we must start with ourselves in the places we live and work.
Read More
Thursday, September 22, 2022 1:01 pm
Hidden Costs
Read More
Thursday, September 15, 2022 1:01 pm
Nothing is free
Read More
Thursday, September 8, 2022 1:01 pm
Spinning the Invoice Printer
Read More
Thursday, September 1, 2022 1:01 pm
So, you want to be a consultant
Read More
Thursday, August 25, 2022 1:01 pm
Well, after a few days, the Great Mother came back. She did not mention gorging herself and neither did anyone else. Great Mother, "We have gotten very far behind, and our time is almost up. Til, can you come forward and read the remaining cases? If we have time, we will take them up at next year's conference." Til came forward.
Read More
Thursday, August 18, 2022 3:16 pm
The Rats took a break for a couple of days. We found a pond for swimming and had a good time. On the way back to the meeting area, we went past a place where the Big Things eat food that they heat up very quickly. Out behind, there were bins full of discarded food, so we had quite a feast. The Great Mother got sick from gorging herself and was very embarrassed. The Great Mother always takes her role very seriously and is very conscious of her decorum. Gorging herself was out of character. She must have felt quite ill, for when we reconvened the Junior Mother was presiding. "Attention, please!" she called us to order. "The Great Mother is a bit under the weather and has asked me to preside over this session. Today, we are going to quickly look at cases where Big Things threatened the companies for which they work. Clerk, please read the cases."
Read More
Thursday, August 11, 2022 3:16 pm
After a brief recess, the Great Mother called us together again. "What is on the docket for today?"
Read More
Thursday, August 4, 2022 3:16 pm
After three lights, the Great Mother called us together again. "We have heard a particularly disturbing story," she began. "It seems as though the Big Things want to be known for protecting this whole place where we live, but some of them take what they call shortcuts at times. The RBI, or Rat Bureau of Investigation, has been looking into this. I'll let them explain." Phineas Kirby came to the front of the room...
Read More
Thursday, July 28, 2022 3:16 pm
By Jim Thompson interpreting for Fos the Rat ... Yes, it is August again and its is corruption month at Paperitalo Publications. We rats have observed in the past year that the human engagement in corruption is not limited to pulp and paper mills. This last statement may sound naïve, but one must understand our methods of communications are rather limited (basically just walking around and talking to each other) so we perhaps don't get all the information Big Things do.
Read More
Thursday, July 21, 2022 3:16 pm
As we wrap up Environmental and Regulations Month here at Paperitalo, we would be remiss if we did not mention the minefield that regulations relating to Human Resources have become.
Read More
Thursday, July 14, 2022 3:16 pm
Don't think you can turn regulations into a marketing advantage. Thinking that a customer base must buy a certain good or service and hence this will make an automatic market for you is a potential mistake.
Read More
Thursday, July 7, 2022 3:16 pm
The general intent of regulations is to keep order in society and keep the population safe. A dictionary definition of regulations is "a rule or directive made and maintained by an authority." My cynical version is this: "those who have power by fiat telling those who own assets what to do." Over the decades, we have seen many actions that follow my definition here in the pulp and paper industry.
Read More
Thursday, June 30, 2022 3:16 pm
A little regulation is probably good, but a lot of regulation chokes business to death.
Read More
Thursday, June 23, 2022 3:16 pm
Sorry about that, but the energy news is coming thick and fast for all of us these days. I am sure you remember old Jim telling you to carefully preserve your boilers, regardless of what form of energy they consume (I have also said these are the only types of idled assets to save). I hope you have heeded my advice. It appears the rapid transition to "Green Energy" sources appears to have some problems.
Read More
Wednesday, June 15, 2022 3:16 pm
A tough subject and one all of us, not matter what side of the negotiating table we sit, should treat with respect, not forgetting our fiduciary duty.
Read More
Thursday, June 9, 2022 1:01 pm
Today, we need to know the delivery status of items way before their expected delivery date. We even need to know what ship they are on and where that ship is at any given moment. As shortages continue, this becomes even more important.
Read More
Thursday, June 2, 2022 1:01 pm
The purchasing department is an area of great opportunities. It is also a place where all the profits of the mill can be dribbled away, and a potential source of grossly unimaginable corruption. The purchasing department must be carefully managed.
Read More
Thursday, May 26, 2022 1:01 pm
As we wrap up this month on energy trends, there is one certainty over which you have complete control. That certainty is this...energy you don't use frees you from others' control. If we think of a pulp and paper mill as a "black box" this means that energy we use inside the mill that we generate ourselves frees us from the vagaries of the markets and external suppliers.
Read More
Thursday, May 19, 2022 1:01 pm
If you have read this column for any length of time, I am about to repeat something you have heard before. I am always in favor of removing obsolete and unused equipment quickly with one glaring exception. That exception is this: power plants.
Read More
Thursday, May 12, 2022 1:01 pm
The answer to dirty energy today seems to be electricity. For mobile transportation, cars and trucks, electricity moves the emissions from many points (tail pipes) to either single points (power stations) or theoretically no points (solar, wind and hydroelectric). The first thing we need to understand is that our choice of energy is cost, ease of use, and emotions. Notice that glaringly absent from this list is science. Energy choices have long since left science out of the equation.
Read More
Thursday, May 5, 2022 1:01 pm
Of course, it is. You ask how I can write a column about this. What we don't realize is how rapidly and how important energy has become to modern societies. The following is a column I wrote for my hometown newspaper about six months ago. While not about energy, it describes a real scenario, that while current, could have easily been widespread conditions about 70 years ago in the United States. The boiler, an important object in this piece, was manufactured only about sixty years ago.
Read More
Thursday, April 28, 2022 1:01 pm
On the Nip Impressions calendar, May is energy trends month. There is hardly a timelier topic, except perhaps food trends, but Nip Impressions does not cover food and my doctor wants me to lose ten pounds, so I try not to think about it. I would guess a good half of the headlines in the popular press today are about energy. These then fall into two categories, security of supply and what to do about, what I will call "dirty" energy.
Read More
Thursday, April 21, 2022 1:01 pm
I was doing some consulting in a mill a number of years ago that had a sign by their entrance that stated they had won some "safety award of the year" some years before the time I visited. I chided them and asked what they had been doing since the time of the award? Obviously, they had not won it again. Unfortunately, about five years after my visit, they had a triple fatality at that mill--contractors on an outage. There are a couple of issues I would like to unpack from my opening paragraph.
Read More
Thursday, April 14, 2022 4:15 pm
Many of us take OTC (Over The Counter) drugs. These can be abused, too. Especially on outages. I'll tell a story on myself...
Read More
Thursday, April 7, 2022 4:15 pm
There was a fatal automobile accident in our neighborhood lately that can serve as an excellent study on how we think when there is little time to sort out the situation. There are lessons here for all of us.
Read More
Thursday, March 31, 2022 4:15 pm
I like to remind people of the following resource any time I get a chance. It is a good way to start off safety month here at Paperitalo Publications. It is simply this. On our website, PaperMoney (www.globalpapermoney.com), we have been keeping track of the industry's safety performance. In its sixth year now, the department, "Reported Risks" is a current chronicle of "Risks: Fires, Fatalities and Catastrophes." It is a good learning resource and a source of endless safety meeting subjects.
Read More
Thursday, March 24, 2022 4:15 pm
It has been over a decade ago that I started talking about manufacturing your own spare parts with additive manufacturing. It is now moving from an interesting idea to a vital necessity. Between logistics problems and world turmoil, the spare parts needed for your machine may not be available. Most, except those of the most critical metallurgy, you can make in your own shop with less skills than a first-class welder or machinist.
Read More
Thursday, March 17, 2022 4:15 pm
Over the years, I have talked about this miserable old mill that I worked at long ago. When I was young, when I had a choice, I always ran towards opportunities that had lots of problems. My philosophy was that situations in trouble were the best way to advance your career. I have never been interested in career safety, it is boring and leads to complacency. So, I end up at this mill, in the prime of my career. It is large, ancient and a mess...
Read More
Thursday, March 10, 2022 4:15 pm
We have more aids for maintenance today than ever before. Detection instruments, storeroom software, built in monitors, training, you name it. Maintenance has never had more help than is available today. So, why do we still have maintenance failures?
Read More
Thursday, March 3, 2022 4:15 pm
Probably after August (Pulp Rats Month), Maintenance Month is my favorite month of the year on the Paperitalo editorial calendar. My dad was notorious for avoiding maintenance. It was an expense he loathed in the same manner as many mill managers and operations executives do. I followed his example for a while, saw the fruits of such policies and became a maintenance fanatic. A couple of old family incidents are in order.
Read More
Thursday, February 24, 2022 4:15 pm
I don't think most mills realize how close we are to interacting with robots every day. The box plants are ahead of us on this. The new Super Plants require about two thirds the employment for the same level of productivity. They are all 110" corrugators and they have a heavy component of robotics. I am expecting to see a flurry of box plant upgrades between now and 2030. Super plants won't be super then--they will be the norm. Back in the papermill, a couple of ready for here and now human aids are available.
Read More
Thursday, February 17, 2022 4:15 pm
In today's world, you may want to think long and hard about how the new or replacement piece of equipment (or other vital supplies) reach your mill. If you can afford to wait 12 - 18 weeks for those special refiner plates to arrive, put them on a ship. If you are losing production or quality every day because you do not have them, fly 'em, the most economical overall cost.
Read More
Thursday, February 10, 2022 4:15 pm
Back in the old days, we used the term "FOB." This meant "Freight on Board." There are other terms these days, but they mean nearly the same thing. One could purchase items "FOB seller's dock" or "FOB purchaser's dock." Internal logistics personnel have, for the last couple of decades, thought it smart to handle the logistics and freight themselves and purchase nearly everything "FOB seller's dock." They think they are saving money and justifying their existence. No more. In today's world, I would recommend that you purchase nearly everything, especially capital goods, "FOB purchaser's dock."
Read More
Wednesday, February 2, 2022 4:15 pm
If you are like most facilities these days, your transportation system, outside the fence, if not in shambles, is at least limping along. What to do?
Read More
Thursday, January 27, 2022 4:00 pm
Give your operations and maintenance folks the help they need to make the project truly successful.
Read More
Thursday, January 20, 2022 4:00 pm
I've often been asked, "how often should our project team meet once our project is under way?" My answer is based on your average spend over the life of the project and at peak times (especially in rebuilds).
Read More
Thursday, January 13, 2022 4:00 pm
I have written assessments on lots of projects. Every one of them follows the same pattern in the same order. Three questions: 1. What are the markets? 2. What are the raw materials? 3. What are the assets (including tangible assets and human assets) that you place between (1) and (2) to have a successful project? If you don't start here, your chances of success are very low.
Read More
Thursday, December 30, 2021 4:00 pm
Most of the people I talk to today have not prepared or managed capital budgets under the conditions we find ourselves in now. Well, I saw my first capital budget in an industrial setting in March of 1970. Perhaps I can help you a bit--we had similar issues back then as those we are facing today--the administration in the White House in those days thought they could control inflation with price controls which caused me to miss two planned 25 cent raises as a co-op student, from $2.75 per hour, to $3.00 per hour to $3.25/hour, over a period of 18 months. Glad I could do my part to help tame inflation; as a student operating on the pay as you go plan (no loans), one makes too much money anyway.
Read More
Thursday, December 30, 2021 4:00 pm
Have you ever had a conversation like this? "I was going to by a car from Brand X because it is cheaper and has more features than Brand Y." "Well, you obviously bought Brand Y. Why?" "Brand X didn't have any in stock and didn't know when they would get any." So, really, in the end, Brand X didn't mean anything because you could not get Brand X. Their price could have been twice the price or half the price of Brand Y, it just didn't make any difference. You may find yourself in this place with certain pieces of capital equipment now. You may have to become a "satisfier" instead of an "optimizer."
Read More
Thursday, December 23, 2021 4:00 pm
I don't think this is a one size fits all question as you look at your marketing going forward. Some customers will be interested in your energy usage, others will be interested in what your products can do to save them costs in their manufacturing and logistics schemes. Please note that in all scenarios in this column, I will be talking primarily about business-to-business sales, not business to consumers.
Read More
Thursday, December 16, 2021 4:00 pm
I recently read an article in the Wall Street Journal which was discussing the write down coming in some energy assets, such as coal reserves, as the economy switches to "greener" energy sources. Like it or not, agree with it or not, there seems to be a move afoot to completely change our acceptable energy sources. You can interpret this as follows: energy is going to get more expensive, a lot more expensive, in this new world.
Read More
Thursday, December 9, 2021 4:00 pm
What concerns me today is that we seem to be more interested in the form of energy rather than its efficiency or cost. Energy has taken on somewhat of an "identity politics" persona. In earlier days, it was security of supply and efficiency. Today it is products of combustion that seems to garner the attention.
Read More
Thursday, December 2, 2021 4:00 pm
If you have read this column for any length of time, you know that old Jim has told you countless times to carefully mothball energy assets that are out of favor, for sooner or later, they will come back into fashion again. This statement is a corollary to my principle, all energy decisions are political. This calendar year has seen a sudden swing to an overwhelming global opinion that climate change is "settled science" and we can't decarbonize fast enough. Couple this with ESG (Environmental, Social and Corporate Governance) principles and boards of directors worldwide are moving at warp speed towards these extremely popular ideas.
Read More
Wednesday, November 24, 2021 4:00 pm
The components and devices to do what I will describe here exists now. Someone just needs to assemble the bits and pieces.
Read More
Thursday, November 18, 2021 1:00 pm
If you think you can't innovate, the problem is purely mental. Creativity can be learned and you can use it in many ways to make your work environment more productive and safer.
Read More
Thursday, November 11, 2021 12:46 pm
Getting innovation right is crucial to optimizing profitability. Too soon, and the equipment may not be able to deliver as promised. Too late and your competition may have already eclipsed you.
Read More
Thursday, November 4, 2021 12:46 pm
There have been many attempts to institutionalize innovation. Sometimes the domiciles of higher education seem to think they have a lock on innovation capabilities. Likely, in some areas, they do. The innovation with near term payoff, however, often takes place at the millsite. It is an activity in which everyone can participate and can be made into a fun (and profitable) activity if structured correctly.
Read More
Thursday, October 28, 2021 12:46 pm
We are in the process of revitalizing and restarting the Light Green Machine Institute, a 501c3 educational institute we created back around 2008. The Light Green Machine Institute's mission statement is "Holistically reducing the environmental impact of pulp and paper processing."
Read More
Thursday, October 21, 2021 12:46 pm
The fourth step in quality is the training and morale of your personnel. All your employees need to be thoroughly trained for the job at hand and not only trained but taught to think so that they can take action when they see something occur that can affect quality.
Read More
Thursday, October 14, 2021 12:46 pm
The third step in Quality is the quality of your raw materials. Some might have thought this is the second step. No, it's the third, for you don't know the quality of raw materials required until you know the quality you are promising your customers.
Read More
Thursday, October 7, 2021 12:46 pm
The second step in Quality is a solid standard of product performance. If you are in the tissue and towel business, these are likely internal standards. If you are in the containerboard or other paper products businesses, these are likely recognized industry standards. You don't know what quality is if you can't define it.
Read More
Thursday, September 30, 2021 12:46 pm
The first step in the path to producing a quality product is the housekeeping in your facility. I know I sound like a broken record, but in truth, housekeeping is the first step in many actions in your mill or converting facility. I have never seen quality products consistently produced in dirty or sloppy facilities. It is just not possible.
Read More
Thursday, September 23, 2021 12:46 pm
If you are the top person on your site, get out of your office and visit your people regularly. I recommend 6 a.m. rounds, with flashlight and small notepad in hand to take notes on what you find (or put them on your phone). Shake hands, get to know your people. If you are over a large facility, don't do it all in a day, but make sure you visit every department at least once per week.
Read More
Thursday, September 16, 2021 12:46 pm
Where human/machine interface is going in our paper mills is hard to guess, it seems to be just at the cusp of arriving as we implement Industry 4.0. On one hand, it will make us better papermakers, but on the other, like my automobile experiences, we will likely have many of the unconscious dependencies...
Read More
Thursday, September 9, 2021 12:46 pm
I was assistant project manager in the engineering department at a mill back in the early 1980's. I have referenced this experience a number of times in this column over the years. One of the upgrades we made at the time was to go from pneumatic controls to digital computer control. This means that the machine, which only a few days ago was operated from benchboard on the floor was now operated from a control room. Now a mere month later, the bench boards are gone. Keep in mind, the crews on this machine had been running it from benchboards for about 14 years...
Read More
Thursday, September 2, 2021 12:46 pm
This is my 52nd September in the workforce. I think management is tougher than ever. Think about it--when I started even OSHA did not exist. People were glad to have jobs and they put up with all sorts of things at work that simply aren't tolerated today, both from the standpoint of society's mores and from a labor regulatory perspective.
Read More
Thursday, August 26, 2021 12:46 pm
Silas, the CEO of REO, wasn't finished last week. He had another story he wanted to relate.
Read More
Thursday, August 19, 2021 12:46 pm
After a few lights of recreation, the Great Mother convened us once again. "Rats," she announced, "Let me introduce the Rat 'Em Out Detective Agency. You can just call them "REO" for short." Six wizened looking old rats came to the front of the room.
Read More
Thursday, August 12, 2021 12:46 pm
The Great Mother called the meeting to order after a short break. "Who has a case for us?" Dis came up the side aisle. There were a lot of rats at the meeting. They had been attracted by the thoughts of a trip to the Big Things capital city and to their building where the biggest rats of all congregated. The Great Mother seemed to be in a benevolent mood, "And what is your story, my child?" "In the mill where I work, there is this female Big Thing. I should say, 'there was.' She is in jail now."
Read More
Thursday, August 5, 2021 12:46 pm
The Rats arrived at the big building with the big half ball on top. What we didn't count on is how bad it stinks inside! Don't know how the Big Things stand it, but after a day or two, we pretty much got used to it. I guess because it has been here a long time and gotten saturated with the residuals of Big Thing's activities causes it to stink so. The Great Mother called us to order. "Thank you for coming. As usual, the Big Things have been working overtime again creating havoc and committing crimes throughout the land. What's on the docket today?"
Read More
Thursday, July 29, 2021 12:46 pm
By Jim Thompson interpreting for Fos the Rat: You Big Things may think we rats are in the dark about your activities. Of course, if you have been reading this column for any length of time, you know that is not true. I (Fos) have been reporting on your misdeeds and malfeasance since August of 2015. Yes, this makes the seventh year Mr. Jim has yielded his column to me for the month of August.
Read More
Thursday, July 22, 2021 12:46 pm
If you have read this series of July columns, you might be thinking I take a dim view of environmentalism principles. I don't--as long as they are measured in their application or make good economic sense. Don't trust the public to be informed. I'll use an example that is not necessarily environmental to prove my point and to show you some of the ways misinformation abounds...
Read More
Thursday, July 15, 2021 12:46 pm
You would be hard pressed to find a topic or concept more universally and shamelessly exploited as a marketing aid than environmentalism. Positive vibes from environmentalism are used by nearly every marketer on earth to show alignment of their products and services with clean air, clean water and less landfill waste. It is a safe bet--who doesn't want clean air, clean water and less landfill waste? Sadly, as an industry, we were a bit slow on the uptake.
Read More
Thursday, July 8, 2021 12:46 pm
Never heard of the Sunrise Movement? You should check them out--www.sunrisemovement.org. On 28 June 2021, they blocked all entrances to the White House to get attention. Some were promptly arrested. One might characterize the Sunrise Movement as Greenpeace on steroids. Youth oriented, the Sunrise Movement has a multifaceted activism focusing on the environment and the Green New Deal. On their website, they list twelve principles. You will have to deal with them.
Read More
Thursday, July 1, 2021 12:46 pm
In the innocent days of the 1970's, the US Environmental Protection Agency was formed. It came into being on 9 July 1970. Other countries had formed similar bodies in the same era. Sweden's was founded in 1967, for instance. Others were formed as late as the 1990's. Back in those days, air and water pollution were spewing forth with little control and little was being done about it. The correct approach was science coupled with appropriate regulations. This has happened worldwide now, by one of two methods.
Read More
Thursday, June 24, 2021 12:46 pm
In this final set of scenarios, I was in the role of Services Manager (responsible for maintenance, engineering, and the technical and power departments) at a mill in Ohio. We were having trouble with contaminants in our recycled fiber supply. The state-of-the-art solution at the time was to replace screen baskets with holes with ones with very small slots. Of course, like all such situations, this solution had spread around the industry as fast as it would on Facebook today (but this was pre-internet). We had screen baskets of the requisite specifications on order, but delivery was months away.
Read More
Jim Thompson, left, is shown with Andy Cochrane, middle, and Allen Hunter.
Friday, June 18, 2021 9:57 pm
On Thursday, June 17, 2021, I had the great pleasure visiting our client, Industrial Air, Inc., of Greensboro, North Carolina. This visit was a year in the making, given the travel restrictions of the lost year of Covid 19.
Read More
Thursday, June 17, 2021 12:46 pm
We were in the middle of engineering and planning a rebuild. Our instrument engineer comes strolling into my office one morning. He's concerned about the delivery of the new distributed control system. On the paper machine, we were going from bench boards on the operating floor (with pneumatic controls) to a digital system in a new control room. Huge change. Our instrument engineer, I'll call him Jeff, was getting conflicting stories from the supplier concerning delivery. I told him to make a couple of more calls, and if he was not happy with the answers he was getting, we would jump on a plane. We jumped on a plane.
Read More
Thursday, June 10, 2021 12:46 pm
As I mentioned last week, we are in a new era of shortages, delays and high costs. Back when many of you engineers and purchasing agents in the mills in the United States were still watching Sesame Street, some of us were going to extraordinary lengths to get the goods our mills needed to stay on schedule and operating. You may need to start thinking this way, too--but be sure to read the safety cautions at the end of this column.
Read More
Thursday, June 3, 2021 12:46 pm
This is the month I talk about procurement. If you buyers or purchasing agents have been moping around for years, thinking you are not getting any recognition, those days are over. Suddenly, you are the center of attention. Pricing and schedule are paramount these days.
Read More
Thursday, May 27, 2021 12:46 pm
As I wrap up the energy columns for this month, I wanted to leave you with a few words of caution.
Read More
Thursday, May 20, 2021 12:46 pm
We have traditionally calculated the investment in energy projects based on savings against alternatives, fuel supply availability or regulatory requirements. What if we drag the marketing folks into the equation and ask them how much more product they could sell or what kind of a competitive advantage they could realize if they could say your facilities and products are more favorable on the carbon question than other manufacturers? Is there a piece of the economic question that could be answered with this discussion?
Read More
Thursday, May 13, 2021 12:46 pm
For decades I have been saying the pulp and paper industry is one of the most exciting sectors in the manufacturing world. It is full of surprises, never ceases to be entertaining and is continually offering new ways to succeed. Now an outfit called Allrise Capital has once again reinforced my beliefs in this thinking.
Read More
Thursday, April 29, 2021 12:46 pm
Regardless of your personal beliefs or the science you (do) (do not) believe, carbon neutrality is in your energy future. There are many high-profile companies and CEOs involved in the "CEO Carbon Neutral Challenge" including our own advertising partner, SAP. The Carbon Neutral Challenge has a list of six guiding principles.
Read More
Thursday, April 29, 2021 12:46 pm
Here in the United States, with a change in administrations, there is often a change in energy policy. It seems no different this time. If you will recall, many times I have said all energy policy is political. This has not changed. My confidential touchstone on energy activity tells me energy research requests are up, too.
Read More
Thursday, April 22, 2021 12:46 pm
Occasionally you will run into a safety situation that is not covered by your training. What to do? My approach to such situations is multi-pronged. Urgency, risk, obvious and unknown are adjectives I would use to describe my approach in these matters, coupled with a heightened awareness of my surroundings.
Read More
Thursday, April 15, 2021 12:46 pm
Last week, we talked about excitement creating dangerous safety conditions. This week let's talk about the opposite--routine creating dangerous safety conditions. Because we work around large machinery, clamp trucks and so forth, which, for the most part behave as they should, we become complacent that about these items. Paper machines can kill--and they have. Clamp trucks can kill--and they have. Dynamic accidents (things flying apart, things falling) are dangerous.
Read More
Thursday, April 8, 2021 12:46 pm
One of the most dangerous times, at work, home or wherever is when we get excited. When excited, we often don't think about safety. How many times have you come into the mill excited (perhaps by the traffic you had just driven in)? How many times have you left the mill excited, with plans to go on vacation or do something else exciting when you got off shift that day? How do we fix this?
Read More
Thursday, April 1, 2021 12:46 pm
The pressure to meet production goals is directly in conflict with safety procedures unless you work hard and creatively to take the conflict out of this scenario, for there is a conflict here, no matter what anyone says. In reality, doing tasks the safest way is often the most efficient way.
Read More
Thursday, March 25, 2021 12:46 pm
I hate boneyards. These piles of junk provide a false sense of security, causing clueless managers to think there is something there that can get them out of a maintenance jam. I haven't kept track, but my perception is that boneyards in my past caused far more problems than they cured.
Read More
Thursday, March 18, 2021 12:46 pm
From July 1925 to December 1970, Popular Science Monthly, a familiar magazine here in the US, ran a feature called Gus Wilson's Model Garage. The typical story was an automobile owner who came to the garage with a vexing car problem. Gus, through his experience, wit and intuition, could figure out the problem and put the driver back on the road, problem solved. In our pulp and paper mills today, perhaps we need more Gus's.
Read More
Thursday, March 11, 2021 12:46 pm
Risking raising the hackles of the IT department, this writer thinks it is time to fold IT into maintenance, for that is what it often is. IT should be held accountable for downtime, just like regular maintenance. Downtime should be broken into scheduled and unscheduled, just like regular maintenance and KPI's should be kept on it. Recently, one major company in our industry experienced a ransomware attack. Within two months, the CEO suddenly retired. Coincidence perhaps, but who on the outside knows?
Read More
Thursday, March 4, 2021 12:46 pm
With experience, one can walk on to an operating floor and determine which faction, operations or maintenance, had the larger influence in a paper mill's design. It is really quite easy. The first giveaway is the width of the operating, or tending, aisle versus the drive aisle.
Read More
Thursday, February 25, 2021 12:46 pm
Is there anything left to be said about maintenance that I have not already said in the last twenty years of writing this column? Yes, there is always something to be said about maintenance. We have more tools, monitoring devices, tracking systems, more than we have ever had before, yet we still have unscheduled maintenance above the levels that should be acceptable in most mills. What should be our standard for maintenance? May I suggest the airline industry?
Read More
Thursday, February 18, 2021 12:46 pm
By accepting graffiti laden railcars on your site, you are approving of a certain level of mediocrity and malaise associated with your business. Further, you are contributing to a plague on society, every time those railcars pass through any town in the country, not just when they are near or on your property. Cleaning up the railcars will be a huge boost to the overall morale of society.
Read More
Thursday, February 11, 2021 12:46 pm
The containerboard industry sorely needs its own "conex" for rolls wider than 110 inches. This needs to be a system that allows rolls to be placed horizontally, or perhaps, at an angle to reduce the height normally achieved by vertical rolls.
Read More
Thursday, February 4, 2021 12:46 pm
Vertical transportation systems, that is, those which stack goods vertically, tend to occupy disproportionately more space than one would first think due to the need to have aisles to retrieve those goods in storage. From a floorspace allocation perspective, only half of the floor is devoted to storage, the other half is devoted to space for retrieval equipment to operate. One system I have seen that overcomes this problem is a vertical storage finished roll warehouse.
Read More
Thursday, January 28, 2021 12:46 pm
In transportation month last year, we talked about electric trucks. We are still talking about electric trucks today and for years to come.
Read More
Thursday, January 21, 2021 12:46 pm
Engineers and scientists have a propensity to save their data. Saved information can come back and bite your company and you. Many a career has been ruined by a fastidious hoarder. Even worse, most think, "it can't happen to me."
Read More
Thursday, January 14, 2021 12:46 pm
Project management is about leadership, not democracy. The objective is to complete the project at the least expenditure of time and money. Treat others with respect, yes, but have clearly defined roles for each person and hold them accountable for their piece, replace them if they cannot successfully accomplish their role. These days, we often spend too much time with our eyes off the prize.
Read More
Thursday, January 7, 2021 12:46 pm
Much of the mismanagement of capital projects could be eliminated, from my experience, if companies adopted the discipline of quasi-public funding project monitoring. These are projects which are not financed through balance sheets but by issuance of tax-exempt or taxable project specific debt. In the last thirty years, I have had experience as the Technical Advisor on 22 such projects (in pulp, paper, energy, steel, medium density fiberboard and cement) with an installed capital base of billions. I have seen a few things.
Read More
Thursday, December 31, 2020 12:46 pm
After nearly fifty-one years in the business, my anecdotal guess is that about half of capital projects are successful, meaning: on time, on budget and fulfilling the original scope. The rest suffer from a myriad of deficiencies.
Read More
Thursday, December 24, 2020 3:31 pm
To wrap up this month on energy columns, I thought I would go to the brightest group I know in the energy business--the National Renewable Energy Laboratory (www.nrel.gov) in Golden, Colorado. NREL had an end of year seminar on the future of energy generation in the United States, 2020 - 2050.
Read More
Thursday, December 17, 2020 3:31 pm
As we continue to talk about energy this month, we would be remiss if we do not bring up hydrogen as a potential fuel. Of course, hydrogen is the "perfect" fuel for combustion, for the "exhaust" is water (H2 + O => H2O). The problem in the past has been that it has not be plentiful or economical.
Read More
Thursday, December 10, 2020 3:31 pm
In a decade, I've moved from being a skeptic to saying some alternative energy sources just may be possible for our industry right around the corner.
Read More
Thursday, December 3, 2020 3:31 pm
Several times in this column over the years, I have told you to not demolish energy assets (that are in good shape) just because you stopped using them. Properly secure and preserve them and wait for policies to change. With an impending change in federal administrations here in the United States, expect an energy priority change within a year. This may come about by regulation changes or economics (the ranking of various fuel costs changing). These changes may be so severe they push some mills out of business.
Read More
Wednesday, November 25, 2020 3:31 pm
This is supposed to be innovation and strategy month but up to this point, I have focused on innovation. Strategy is important, too, but strategy must be focused on solid science, statistics and mathematics. I have seen many strategic initiatives fail over the years. That does not mean we should stop doing them, it means we should make sure our foundation was solid.
Read More
Thursday, November 19, 2020 12:45 pm
We usually think of innovation as being creative and coming up with some gee whiz new idea. If you have been in business for more than a week, it is easier than that. Just use a critical eye to eliminate the unnecessary. The unnecessary comes in many forms.
Read More
Thursday, November 12, 2020 12:45 pm
There are many failures in innovation. One chronic failure to keep in mind is to be aware of your surroundings. You may think you have a fantastic idea. But if it is not obvious that it solves a problem or it is a solution more complicated than the original problem, it likely will fail.
Read More
|
|
|
|
