Neopak exists to open the world’s eyes to the unlimited possibilities of paper packaging by delivering smart paper packaging solutions that enhance our customers’ brands and profitability. At Neopak we support a vision. A vision of lasting relationships, world-class efficiency, meaningful innovation, thoughtful leadership, business partnering and a fresh take on old habits.
WHAT WAS IS NEOPAK’S PROBLEMS AND NEEDS?
Paper breaks or other process interruptions, equipment failure and quality negatively impact Neopak's profitability. Neopak's challenge was to change from reactive management to pro-active management of conditions that precede poor performance. Knowledge and experience are prerequisites for the implementation of pro-active management - the question was whether process data analysis can deliver insight and enhance operational personnel's knowledge / understanding of the process.
Neopak also expressed the need to utilise production process data to determine their operational risk exposure. Overall Equipment Effectiveness (OOE) was used but it failed to identify what section or module in the plant caused poor performance. The need existed to generate a quantitative measure that describe performance at modular level e.g. what is the ability of the stock blending section to comply with specific operating conditions, or how well did the respective drying sections comply with predefined baselines.
Time-in-State's functionality provided an opportunity to quantify modular performance. After deriving baseline definitions across the plant it will be possible to track compliance of each section's (or module's) contribution to performance. If all sections (modules) comply with their respective baseline definition the chances of meeting production targets will increase.
HOW DID TIME-IN-STATE®(TiS) HELP?
Time-in-State®(TiS) illustrated how much value can be extracted from process data. The technology facilitated a modular breakdown of the production process. Optimum Operating Envelope (OOE) is a new performance metric that enables performance measurement within sections / modules. E.g. it is possible to report that a specific gearbox and motor complied 93% with OOE. This is done by using a multi-variable time based status assessment providing insight into changing behaviour - the same approach applies the process modules such as the blending section.
Time-in-State® facilitated systems thinking, innovation, training and continuous improvement.
“This predictive capacity is by far one of the strongest features in the IME Time-in-State®(TIS). The system can, in fact, alert operators, if the process is starting to deviate from the optimum plan.”
HOW THAT ENDED IN SUCCESS
Time-in-State® delivered an accurate assessment of operational risk exposure. For example, after defining the Optimum Operating Envelope (OOE) for the blending section Time-in-State (TiS) indicated that this section complied with the optimum envelope for only 47% of the time. Neopak launched specific intitiatives using results produced by Time-in-State® analytics. The blending section's compliance with OOE consequently increased to 65% within five weeks. This improvement translated into improved production output.
Time-in-State®(TiS) allowed Neopak to obtain early warning detection in deteriorating performance and detected conditions leading up to the poor performance and/ or process interruption. This will ensure more growth and success in Neopak's growth and sustainability.