By Richard C. Dow
1. FIBER - (BALES - ROLLS - WET LAPS - PALLETS - BUNDLES)
1.1 Job descriptions and employee knowledge of job functions
1.2 Instructions delineating specific job functions and data recording
1.3 Delivery scheduling and notification procedures
1.4 Purchasing and receiving departments coordination procedures
1.5 Documentation: bills of lading - purchase orders - checklists
1.6 Verification of type, condition and quantity of material ordered
1.7 Methods for movement to and inventory of fiber in storage areas
1.8 Recording procedures: weight - unit count - volume
1.9 Moisture verification methods
1.10 Product identification and labelling
1.11 Condition: excellent - good - wet - dirty - frozen - broken/loose bales
1.12 Disposition procedures for off-standard and rejected fiber
1.13 Procedures for rectification of quality/quantity problems
1.14 Inventory procedures
a. Personnel responsible and methods employed
b. Documentation and data recording
c. Variances
1.15 Disposition of damaged, wrong, surplus and/or obsolete material
1.16 Motors: kW, function, condition and estimated operating hours/day
1.17 Lighting - heating - ventilation - weatherized - housekeeping
1.12 Safety issues: shoes - eye protection - hardhats - walkways - handrails
1.19 Condition: elevators - conveyors - forklifts - scales - hoists - gates
1.20 Fire protection - sprinkler system - extinguishers - alarms
2. DRY MATERIALS – (BAGGED - BULK BINS - BULK CARRIERS - DRUMS)
2.1 Employee knowledge of job functions
2.2 Instructions delineating specific job functions and data recording
2.3 Delivery scheduling and departmental notification procedures
2.4 Purchasing and receiving departments coordination procedures
2.5 Documentation: bills of lading - purchase orders - checklists
2.6 Verification of type, condition and quantity of material ordered
2.7 Procedures for moving material to storage areas
2.8 Weight, unit count, volume, and data recording procedures
2.9 Moisture verification methods
2.10 Product identification and labelling
2.11 Material condition: wet - dirty - frozen - broken - leaking
2.12 Disposition of damaged, wrong, excess and/or obsolete material
2.13 Procedures for notification and rectification of identified problems
2.14 Inventory procedures
a. Personnel responsible and methods employed
b. Documentation and data recording
c. Variances
2.15 Disposition of damaged, wrong, excess and/or obsolete material
2.16 Motors: kW, function, condition and estimated operating hours/day
2.17 Lighting - heating - ventilation - weatherised - housekeeping
2.18 Safety issues: shoes - eye protection - hardhats - walkways – handrails
2.19 Condition: elevators - conveyors - hoists - forklifts - tanks - chests - gates
2.20 Fire protection - sprinkler system - extinguishers - alarms
3. LIQUID MATERIALS – (DRUMS – BINS – TANKS – BULK CARRIERS)
3.1 Employee knowledge of job functions
3.2 Instructions delineating specific job functionsand data recording
3.3 Delivery scheduling and department notification procedures
3.4 Purchasing and receiving department’s coordination procedures
3.5 Documentation: bills of lading - purchase orders - checklists
3.6 Verification of type and quantity of material ordered
3.7 Weight, unit count, volume, and data recording procedures
3.8 Solids, consistency and strength verification methods
3.9 Storage capacity, overfill and leakage procedures
3.10 Procedures for rectification of identified problems
3.11 Inventory procedures
a. Personnel responsible and methods employed
b. Documentation and data recording
c. Variances
3.12 Disposition of spoiled, wrong, excess and/or obsolete material
3.13 Motors: kW, function, condition and estimated operating hours/day
3.14 Condition: valves - piping - pumps - meters - forklifts - gates
3.15 Lighting - heating - ventilation - weatherized - housekeeping
3.16 Safety issues: shoes – eye protection - hardhats - walkways - handrails
3.17 Fire protection - sprinkler system - extinguishers - alarms
4. WRAPPING - PACKAGING MATERIALS (CORES –WRAPPERS - HEADERS - CARTONS - PALLETS - GLUE - TAPE - STRAPPING - SKIDS)
4.1 Employee knowledge of job functions
4.2 Instructions delineating specific job functions and data recording
4.3 Delivery scheduling and notification procedures
4.4 Purchasing and receiving departments coordination procedures
4.5 Documentation: bills of lading - purchase orders - checklists
4.6 Verification of specific type and quantity of material ordered
4.7 Procedures for movement of material to storage areas
4.8 Procedures for rectification of identified problems
4.9 Inventory procedures
a. Personnel responsible and methods employed
b. Documentation and data recording
c. Variances
4.10 Disposition of damaged, wrong, excess and/or obsolete material
4.11 Motors: kW, function, condition and estimated operating hours/day
4.12 Condition: elevators - forklifts - ramps – dockplates - gates
4.13 Safety issues: shoes – eye protection - hardhats - walkways - handrails
4.14 Lighting – heating – ventilation – housekeeping
4.15 Fire protection – sprinkler system – extinguishers - alarms
5. MAINTENANCE - REPAIR & MILL OPERATING SUPPLIES
5.1 Employee knowledge of job functions
5.2Instructions delineating specific job functions and data recording
5.3 Delivery scheduling and notification procedures
5.4 Purchasing and receiving departments coordination procedures
5.5 Documentation: bills of lading - purchase orders - checklists
5.6 Verification of type and quantity of material ordered
5.7 Procedures for movement of material to storage areas
5.8 Procedures for rectification of identified problems
5.9 Inventory procedures
a. Personnel responsible and methods employed
b. Documentation and data recording
c. Machinery and equipment spares
d. Variances
5.10 Disposition of damaged, wrong, excess and/or obsolete material
5.11 Condition: elevators - forklifts - ramps - dockplates
5.12 Safety issues: shoes - eye protection - hardhats - walkways - handrails
5.13 Lighting - heating - ventilation - housekeeping
5.14 Fire protection – sprinkler system – extinguishers - alarms
6. FUEL SUPPLIES & BOILER - WATER & EFFLUENT TREATMENT CHEMICALS
6.1 Employee knowledge of job functions
6.2 Instructions delineating specific job functions and data recording
6.3 Delivery scheduling and notification procedures
6.4 Purchasing and receiving departments coordination procedures
6.5 Documentation: bills of lading - purchase orders – check Lists
6.6 Verification of type and quantity ordered
6.7 Fuel moisture, solids, strengths and Btu verification methods
6.8 Pumps, valves, meters and data recording procedures
6.9 Storage capacities and overfill procedures
6.10 Procedures for rectification of identified problems
6.11 Inventory procedures
a. Personnel responsible and methods employed
b. Documentation and data recording
c. Data verification - records balancing - variances
d. Machinery and equipment spares
e. Fuel - oil – lubricants – chemicals
6.12 Safety issues: shoes – eye protection - hardhats - walkways - handrails - gates
6.13 Motors: kW, function, condition and estimated operating hours/day
6.14 Lighting - heating - ventilation - housekeeping
6.15 Fire protection - sprinkler system - extinguishers - alarms
7. STOCK PREPARATION & DEINKING - AREAS OF REVIEW
7.1 Employee knowledge of job functions
7.2 Instructions delineating specific job functions and data recording
7.3 Start-up and shut-down procedures
7.4 Clarity and distribution of standard furnish instructions
7.5 Scheduling versus availability of furnish materials
7.6 Verification of adherence to standard furnishes
7.7 Error reporting and rectification procedures
7.8 Weighing, measuring, metering: methods and equipment
7.9 Mill broke: grade & color segregation and handling procedure
7.10 Pulper loading equipment: lifts - conveyors - forklifts
7.11 Pulper loading procedures: quantities - temperature - consistencies
7.12 Additives and dyes: storage and application methods
7.13 Pulping cycle times and dumping procedures
7.14 Disposal of over run,contaminated and nonstandard furnishes
7.15 Sewer loss monitoring and recording procedures
7.16 Wash-up and chest/tank cleaning procedures
7.17 Wet lap production and storage
7.18 Reporting procedures for malfunctioning equipment
7.19 Capacities: tankage - chests - valves - pumps - piping
7.20 Process control equipment & instrumentation
7.21 Spares: motors - pumps - valves - plates - screens- rotors - impellers
7.22 Motors: kW, function, condition and estimated operating hours/day
7.23 Safety issues: shoes - eye protection - hardhats - walkways - handrails - gates
7.24 Lighting - heating - ventilation - housekeeping
7.25 Fire protection - sprinkler system - extinguishers - alarms
8. PAPER MACHINE OPERATIONS - AREAS OF REVIEW
8.1 Employee knowledge of job functions
8.2 Instructions delineating specific job functions and data recording
8.3 Specific instructions for start-up and shut-down procedures
8.4 Wire and clothing change procedures
8.5 Washups, boil-out and hood cleaning procedures
8.6 Size preparation and size press operations
8.7 Grade change procedures
8.8 Weighing procedures at reel & re-winder: production - trim - rejects
8.9 Broke weighing, segregation & handling procedures
8.10 Production measurement at shift changes
8.11 Compliance with roll diameter requirements
8.12 Method of determining quality standard for the various grades
8.13 Correlation of process control equipment with laboratory tests
8.14 Splicing, defect detection flagging and sampling procedures
8.15 Lighting - ventilation - housekeeping
8.16 Spares: clothing - rolls - blades - motors - pumps - valves - bearings
8.17 Motors: kW, function, condition and estimated operating hours/day
8.18 Safety issues: shoes - eye protection - hardhats - walkways - handrails
8.19 Fire protection - sprinkler system - extinguishers - alarms
8.20 Emergency shutdown procedures
9. REWINDING OPERATIONS - AREAS OF REVIEW
9.1 Employee knowledge of job functions
9.2 Instructions delineating specific job functions and data recording
9.3 Start-up and shut-down procedures
9.4 Reporting procedures for unflagged defects
9.5 Defect detection – sampling procedures
9.6 Weighing procedures: good production
9.7 Disposition of production excess to customer’s order
9.8 Broke weighing, segregation & handling procedures
9.9 Production measurement at shift changes
9.10 Scheduling versus rewinding backlog and storage space
9.11 Department lighting - ventilation - housekeeping
9.12 Spares: motors – slitters - bearings
9.13 Motors: kW, function, condition and estimated operating hours/day
9.14 Safety issues: shoes – eye protection - hardhats - gates
9.15 Fire protection – sprinkler system – extinguishers - alarms
10. WAREHOUSE-SHIPPING OPERATIONS - AREAS OF REVIEW
10.1 Employee knowledge of job functions
10.2 Instructions delineating specific job functions and data recording
10.3 Storage & rack system
10.4 Shipment verification procedures
10.5 Inventory control procedures
a. Methods employed
b. Documentation and data recording
c. Variances
10.6 Shipment scheduling
10.7 Damaged goods processing
10.8 Equipment: conveyors - fork lifts - dock plates
10.9 Lighting - heating - housekeeping
10.10 Safety issues: shoes - eyeprotection - hardhats
10.11 Security - access by non - employees (truck drivers)
10.12 Fire protection - sprinkler system - extinguishers - alarms
11. ENGINEERING – MAINTENANCE - ENVIRONMENTAL - AREAS OF REVIEW
11.1 Employee knowledge of job function
11.2 Instructions delineating specific job functions and data recording
11.3 Maintenance work order procedures
11.4 Multi-shift coverage practices
11.5 In-house capabilities:(grinding/sharpening/turning etc)
11.6 Organisation of mill spares storeroom
11.7 Maintenance scheduling functions
11.8 Pre-costing work orders
11.9 Waste of and/or improper use of repair material
11.10 Major engineering/maintenance problems
11.11 Effuent/sludge treatment facilities
11.12 Environmental issues and concerns
11.13 Motors: kW, function, condition and estimated operating hours/day
11.14 Pumps: efficiencies
11.15 Conservation discipline: electricity - water - heat
11.16 Ventilation/Insulation
11.17 Steam generating efficiencies
11.18 Condition: steam lines & valves
11.19 Cogeneration potential
11.20 Safety issues: shoes - eye protection - hardhats
11.21 Fire protection - sprinkler system - extinguishers - alarms
11.22 Plant security: access by non-employees to include maintenance contractors
12. ADMINISTRATIVE & ACCOUNTING SERVICES
12.1 Employee knowledge of job functions
12.2 Instructions delineating specific job functions and data recording
12.3 Organisation of the accounting department
12.4 Overview of the cost accounting system and procedures
12.5 Evaluation of function and u tility of all mill routine reports
12.6 Correlation - actual vs reported costs and inventories
12.7 Method of establishing costs for new or variances in existing grades
12.8 Dissemination of cost data to managers and mill employees
13. QUALITY CONTROL SERVICES & SYSTEMS
13.1 Employee knowledge of job functions
13.2 Instructions delineating specific job functions and data recording
13.3 Shift staffing levels
13.4 Equipment and Instrumentation
13.5 Quality decision making - process and coordination
13.6 Standards awareness by operations personnel
13.7 Major quality problems: type/grade/frequency
13.8 Data communications and distribution procedures to operations personnel
13.9 Safety issues: shoes - eye protection - hardhats
14. CUSTOMER SERVICES OPERATIONS
14.1 Employee knowledge of job functions
14.2 Instructions delineating specific job functions and data recording
14.3 Order entry procedures
14.4 Ready date revision procedures
14.5 Inventory control procedures
14.6 Billing procedures
14.7 Complaint handling: promptness – department/emploee notification
14.8 Back order, stock entry, and field rejection procedures
14.9 Production scheduling
14.10 Disseminating positive & negative information to operations employees
14.11 Posting customer complaints
14.12 Employees accompanying sales staff on customer compaints
15. PURCHASING DEPARTMENT
15.1 Employee knowledge of job functions
15.2 Instructions delineating job specific functions and data recording
15.3 Using department’s participation in purchase decisions
15.4 Policies and procedures re’ purchasing decisions for:
a. Material handling/warehousing equipment
b. Raw materials - chemicals - wrapping - packaging materials
c. Maintenance, repair and operating supplies
d. Equipment leasing/rental agreements
e. Capital equipment purchases
16. HUMAN RESOURCES DEPARTMENT
16.1 Employee knowledge of job functions
16.2 Instructions delineating specific job functions
16.3 Training programs for operations personnel
16.4 Basic personnel management policies
16.5 Employee health & insurance programs
16.6 Union activities: grievances - management/workforce rapport
16.7 Emergency response procedures
16.8 Government, regional and local regulatory issues
a. Training programs: Injuries - accidents – fire
b. Employee incentive and recognition programs
16.11 Community liason activities
17. MARKETING & SALES DEPARTMENT
17.1 Sales staff members paper industry experience
17.2 Knowledge of product line and its applications in the graphic arts industry
17.3 Awareness of manufacturing costs of specific grades
17.4 Sales analysis: direct, merchant & distibutors: volume and profitability
17.5 Marketing & promotion methods: samples - brochures - trade shows
17.6 Decision process : special furnish - minimum quantities - rush deliveries
17.7 Awareness of, and response to competitive products and pricing
Richard C. Dow, Cape Elizabeth, Maine, USA, is a consultant specialising in feasibility studies for the development of tissue mills and evaluating manufacturing and converting process efficiency. E-mail: rcdow@maine.rr.com
