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Interstate
Paper Industries, Egypt-based tissue mill, implements new plant layout design
to improve operations and plant safety meeting international standards.
As
part of the on-going strategy to improve plant efficiency and cost effective
production, INDEVCO Paper Making Division launched the “Paper Machine 2”
transfer project in 2012. The project aimed to improve operations at both
member tissue mills by shifting the second paper machine from Unipak Tissue Mill facilities in Halat, Lebanon, to Interstate Paper Industries (IPI) plant
in Sadat City, Egypt.
The
successful project signified the initial stage of a large scale plan to
implement world-class safety and quality standards and transform “Paper Machine
2’s” new facility into an exemplary plant.
Karim
Frem, Project Manager, focused on implementing a framework for safe operations,
starting from the plant’s layout design. The strategy coincides with Interstate
Paper Industries’ General Manager, Raja Mouracade’s belief that “safety and good housekeeping start with a well designed
plant layout”.
Steps
to Elevate Operations & Safety at Interstate Paper Industries
Interstate
Paper Industries applied best practices and principles, including raised floors
for fast and modular expansions, one level operation for ease of control, and
visual management among others. Furthermore, in order to strategically organize
the plant, the tissue mill began implementation of 5S methodology, leveraging
on the know-how of INDEVCO Paper Containers Continuous Improvement unit.
The
5S methodology aims to improve safety, downtime, efficiency, quality, and
workplace morale through 5 phases: Sorting, Setting in Order, Shining
(systematic cleaning), Standardizing, and Sustaining.
5S
Methodology at Interstate Paper Industries
The
Continuous Improvement unit provided Interstate Paper Industries with a set of
design standards dictating how to organize a shop floor based on the 5S
methodology. The unit created the standard by combining years of
experience in 5S application and extensive research on globally renowned
standards.
INDEVCO
Paper Containers’ color coding standards organize the plant into colors,
putting in place a system for employees to identify and evaluate the level and
type of hazard at each location within the plant. In terms of
housekeeping, the color codes help keep the floor well organized and clear, and
ensure that the roads and walkways always lead to the correct destination.
The
unit continuously revises and improves the color code standards. With the
core framework
at its peak, however, upcoming revisions will deal with specific exceptions
that may be faced during the implementation of the
standard.
INDEVCO Paper Making division member companies include Interstate Paper Industries in Sadat City, Egypt and Unipak Tissue Mill in Halat, Lebanon. These tissue mills manufacture virgin and recycled jumbo parent tissue reels for converters of away-from-home (AFH) tissue, household tissue and personal care hygiene disposables in Europe, the Middle East and Africa (MENA).
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