Management of Innovation at Solvay Paperboard

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Management of Innovation at Solvay Paperboard

• K. G. Rajan

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INTRODUCTION

• Solvay Paperboard is a 100 recycled
  containerboard mill in Syracuse, N.Y.
• Partnership of four independent corrugated box
  manufacturers
• Mini-mill concept, built to last
• Team concept work culture

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• 1994 PM1

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• 1999 PM2

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• 2002 PM3

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• Not your average paper company!
• We call it thinking out of the box
• You can call it INNOVATION

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EXAMPLES OF INNOVATION AT SOLVAY PAPERBOARD
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Innovation Doesnt Necessarily Mean Faster is
Better

• Example PM1 was designed for 1000 1500 FPM
  using equipment suited for 2000 3000 FPM
• Result 95 uptime, low cost of maintenance

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Innovation Can Be Something As Simple As
Standardization

• Example All electrical components from one
  supplier
• Result Optimal training, minimum expert
  services

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Innovation Can Be Operator Access to Controls
Everywhere

• Example PM1 first machine with complete Mill DCS
  in every bench board
• Result Operator efficiency

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Innovation Can Be Using Ideas from Other Processes

• Example Walking floor from trucking wire
  cutter from PP
• Result Operator safety, reduced personnel

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Innovation Can Be Inspecting and Sorting Garbage

• Example First Mill to classify OCC by grade
• Result Process stability

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Innovation Can Be Improving Quality of Work Life

• Example Automated grapple hoist
• Result Minimize brain numbing from years of
  repetitive tasks

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Innovation Can Be Applied to Safety and
Housekeeping

• Example Concept of breakfast under the pulper
• Result Clean, safe Mill

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Innovation Can Come From Any Source

• Example Location of locker rooms came from a
  postman
• Result People are always in the middle of the
  action

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Innovation Can Be Commercial

• Example Giving suppliers ownership of a complete
  valve package
• Result Owner can focus on making the project
  successful

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Innovation Can Be About Many Small Things

• Example Pumps without seal water
• Result Lower operating cost (water, energy,
  effluent)

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Innovation in Process Design

• Example Segregate solid waste streams
• Result Downstream recovery (plastic to
  cogeneration, fibers to animal bedding)

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Innovation is Learning from Other Countries

• Example Anaerobic effluent treatment
• Result Minimal operating costs

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Innovation Can Be in People Systems

• Example Empowering the workforce, pay for skills
• Result Highly qualified, self-motivated
  technicians

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But Most Importantly, Innovation is About
Courage!

• Investor courage to invest
• Designers courage to put their reputation on the
  line
• Supplier courage to manage innovation
• Operator courage to take responsibility
• Management courage to stay out of the way

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Thank you!