Optimisation - Mill Tuning
Mill Tuning is a very interesting opportunity to optimize machines, mills, manufacturing processes and to save money.
The cost-benefit ratio is mostly very big here and in many cases the optimisation is leading in an immediate net costs discharge or has amortization times of
only few months up to 1-2 years.
Further the capital costs are low and can be financed from own resources.
Starting points for the optimisation
- Change in the organization. E.G. shifts, number of the employees,
bonus wage, organized service and maintenance, etc.
- Supply and collection of materials at the right time, at the right place in correct
quality and quantity.
- Changes in the machine control system, e.g., shortening of timer times or
rising of conveyor speeds
- Adaptation of current quality of raw material and finished goods to the necessary target
- Supplying of information to the right time at the right place and with correct content
- Reduction or removal of technical disturbances as a result of construction mistakes or
- Removal of software mistakes in the control system (Debugging).
Most of the control systems are unique and naturally mistake-afflicted.
Tuning of Finger Jointing lines
Finger jointing lines take in the total capacity and with it, in the overall profitability
of a glued timber factory a central function.
As a rule they are the bottleneck in manufacturing.
8 of 10 plants run under their target capacity and nearly all plants are running below their
technically possible capacity.
On this occasion, neither a lot of money must be invested to increase the output nor is it necessary to buy immediately a new line.
According to our experiences, most Finger Jointing lines hide a huge increase potential,
that besides, can be released relatively easily.
Mill Tuning - a profitability example:
Increase of finger jointing performance about 5%.
Within this increase, main costs will stay essentially the same.
Acceptance: the plant makes per shift i.a. approx. 10,000 linear meters glulam lamellas.
This corresponds approx. 24,000 cbms / year.
5% of increase = approx. 1,200 cbms / year.
Taken a conservatively gross margin of 25% and a GL price of 400, - EUR,
5% increase of volume will result an
additional gross margin of 120,000 EUR / year.
With accepted costs for the tuning of 40,000 EUR, the procedure will be completely paid off already after 4 months.
Changes in the organization, staff, storage and logistics mostly concern the complete company or at least the department of finger jointing / gluing.
Naturally, this cannot be implemented very easily. The power of usual,
but sometimes the resistance of employees make this more difficult.
Therefore, we recommend as a first step, to optimize the finger-jointing line, especially
the control system.
In our experience, every system has potential to increase performance by changing the software.