End of the Summer Presentation_Alden

Summer 2016: Final Presentation

Alden AndersonTechnical Summer Intern

8/8/2016

SAFETY Projects

• As part of a follow-up for PM2 felt side coating filter safety issue investigated possible causes for resin build-up on PM2 filters

• Performed the Annual DOLPHIN chemical audit for Material Prep and QA

Resin Build-up on PM2

• Investigated build-up of resin on PM2 filter as a response to recent back injury

• Collected samples of sub coat daily to take readings on pH and viscosity in order to create a base line data

Resin Build-up on PM2

• Created updating graphs that show pH and viscosity over time

12/30/1899 9/8/1913 5/18/1927 1/24/1941 10/3/1954 6/11/1968 2/18/1982 10/28/1995 7/6/2009 3/15/20230

100

200

300

400

500

600

700

800

900

1000

Loop Coating Viscosity

Date

Visc

osity

(cP)

*Samples from PM2 Feltside Tank

*Red means build-up was seen

Resin Build-up on PM2

12/30/1899 9/8/1913 5/18/1927 1/24/1941 10/3/1954 6/11/1968 2/18/1982 10/28/1995 7/6/2009 3/15/20235

5.5

6

6.5

7

7.5

8

8.5

Loop Coating pH

Date

pH

*Red means build-up was seen

*Samples from PM2 Feltside Tank

Resin Build-up on PM2

• Collected samples of sub-coat and resin on day when there was build-up and sent to Appleton for testing

FS Loop Sub-Coat Resin Build-Up Sample FS Return Sub-Coat

Dolphin Chemical Audit

• Investigated list of chemicals in question to see if they were still used

• Initially 83 chemicals were unknown in Material Prep and 11 were unknown in QA

Dolphin Chemical Audit • After the investigation was complete, Matt and I had

ascertained information on all of the chemicals in QA and 64 of the chemicals on the Material Prep list.

• List was then sent to Johnna Fries so chemicals could be updated in DOLPHIN with SDSs or archived

QUALITY Projects

• Lead Kaizen to reduce/eliminate Roll Mislabeling Complaints and Non-Conformances

• Developed a Roll Quality Vertical Audit Process • Helped with Development of a Finished Roll

Quality/Splice Audit • Worked to loosen the 20% Curl Reject Limit for

MM 4781 on PM3 and PM2

Kaizen for Stamping/Labeling • Learned what a Kaizen

entailed from the CI Department

• Investigated Non-Conformances from the last year about stamping and labeling

• Learned how incredibly valuable operator input was as they helped identify problems I would have never seen

Kaizen for Stamping/Labeling

• At the Kaizen the root causes of the Stamping/Labeling issue were identified

• Created a list of countermeasures to reduce/eliminate the issue– These included roll audits, creating SOP for roll

labeling, applying all CB roll labels at Head roll station, informing operators on customer complaints and NCs, and highlighting roll position on belly tags

– Weekly meetings to monitor progress

Roll Quality Vertical Audit

• Creation of the Roll Quality Vertical Audit began with the idea of raising awareness about our current specs

• Then the major issues were identified in order to create an audit sheet

Roll Quality Vertical Audit

• Implementation of the Audit involved numerous trials and modifications

• Creation of a record system in order to monitor progress of the audit

• Carrying out the audits themselves

Finished Roll Quality Audit

• This audit stemmed from a desire to inspect splices

• Doug Guise’s old audit was found and modified to meet new specs

• Audit is currently being trialed

Loosen 20% Curl Reject Limit on MM 4781

• Particular grades on PM3 are seeing a problem where in order to get the 50% humidity curl test to Target the 20% curl is being run in pre-control

• Decided to focus on MM 4781 for proposing the change

Loosening 20% Curl Reject Limit

• Pulled data from June 2015 to present to investigate where exactly changes need to be made

• Using histograms created a proposal for creating new lower limits

Loosening 20% Curl Reject Limit

• Proposed new 20% curl lower limits for MM 4781

• Put in a formal request for a spec change

Other QUALITY Projects

• Helped monitor 20# Cream Bond to ensure it met quality requirements

• Established collaborative testing program for kCoF tester

• Looked into trends for the difference between the 2 minute and 30 second TI

• Improved TSGs for the QA laboratory equipment • Created defect books for each Paper Machine and

QA Lab

20# Cream Bond Quality

• Helped investigated complaints by C&J to determine predicament

• Watched 20# Cream Bond run and inspected splices during run

kCoF Testing Program

• Created to prevent kCoF test from drifting

• Contacted Ellen Roberts and involved Appleton it testing

• Created sheet to record and compare test values from both facilities

• Status-Starting this month

2 Minute VS. 30 Second TI to Monitor Print Speed

• Investigated benefit of a graph of the difference between 2 minute and 30 second TI

• Decided difference graph was redundant if we have 30 second and 2 minute graphs already

18-Sep-14 00:00 27-Dec-14 00:00 06-Apr-15 00:00 15-Jul-15 00:00 23-Oct-15 00:00 31-Jan-16 00:00 10-May-16 00:00 18-Aug-16 00:00-20

-15

-10

-5

0

5

10

15

Difference for CB TI: 2 Min Minus 30 Sec

Improved TSGs for QA Lab

• Improved TSGs for – Contact Angle Test– Ink Penetration Size Test – Mullen Burst Strength Test – Stiffness Test – Caliper Test– kCoF Test – Color Touch Test– Scott Internal Bond Test

Defect Books

• Located any remaining defect books • Filled Defect Books with defect sheets and put

them in proper locations for future use

What I Learned

• The importance of Safety • The value of feedback • The benefits associated with teamwork • A understanding of what it is like to work in an

industrial environment