Pulp and Paper Manufacturing

Pulp and paper manufacturers have an essential role in today’s economy, turning materials such as wood and recycled paper into the many cellulose-based products we rely on, such as paper, labels, and packaging. Converting, where paper is transformed into other products, is an area where automated production monitoring is particularly impactful. Many of the pulp and paper companies who benefit from utilizing the Vorne XL production monitoring system are converters, monitoring processes in which large rolls of material are turned into a broad range of finished goods (e.g., sheeted paper, filters, wet wipe packs, cardboard packaging, etc.).

Whether maintaining precise process speeds, reducing roll changeover and splicing times, or reducing scrap and trim, automated solutions such as Vorne XL provide a clear picture of production, accurately quantifying all sources of lost production time, and establishing a comprehensive data foundation for continuous improvement.

XL moves pulp and paper operations far beyond manual data capture to gain critical insights for driving process improvement and effectuating change with 100+ metrics and 20+ data dimensions including OEE, Six Big Losses, TEEP, and Labor Efficiency.

Other benefits of XL that our customers love include no software to install, no servers to maintain, no recurring fees, and no contracts. Instead you get unlimited users, free technical support, a 3-year warranty, and free software updates. All in an inexpensive, off-the-shelf product.

Driving Improvement for Pulp and Paper Manufacturing

Many of our pulp and paper customers have an added focus on sustainability while manufacturing a diverse range of products, cost effectively, and with an eye towards continuous improvement.

The Vorne XL Productivity Appliance empowers pulp and paper manufacturers to monitor their processes in real time, improve throughput, and maximize efficiency, all while preserving the integrity of their products. XL drops onto your existing process, making it a quick and easy solution that requires little to no changes on the manufacturing line. This is a unique and critical advantage of Vorne XL.

Key Benefits for Pulp and Paper Manufacturers

Vorne XL is completely agnostic to the type of equipment in your manufacturing process. This is a huge advantage as you can easily apply XL to any process and get the same deep wealth of information. XL includes I/O to integrate with your process, a scoreboard for your operators, and built-in reporting for your managers. Even better, it easily and incrementally scales from machine to enterprise.

Monitor your converting lines, rotary cutters or die cutters, and a variety of other equipment with one solution, quickly seeing benefits such as:

Understand Changeover Variance Changing master rolls and splicing material is often a major loss of production time for pulp and paper manufacturers. Vorne XL provides accurate analysis of your changeover events, offering insights that help you set ambitious but attainable target times.
Maintain Target Run Rates Utilize the real-time plant floor scoreboard and browser-based web interface to monitor current or historical run rates and speeds, ensuring the process is running optimally and meeting customer demand.
Historical Part Run Data Reducing variance between shifts in operating the line is critical to manufacturing efficiently and effectively. Use historical part and shift data to develop best practices and to tailor specific training and corrective actions.
Automated Enterprise Reporting XL enables you to automatically generate and send production reports for individual lines and for data that is aggregated across your entire plant - or even multiple plants. Stay informed with timely reports that place the appropriate data into the hands of the right people at the exact time they need it.
Operator Comments Empower your operators or maintenance staff to record additional comments on events such as changeovers, downtime, or part runs, contributing to more robust reporting. Share any information that is useful for shift handoffs or process improvement over time.

Metrics, Dimensions, and Dashboards

Vorne XL provides you with an incredible data foundation and an outstanding suite of reporting tools to effectively drive your continuous improvement, lean manufacturing, and digital transformation initiatives. With XL you get immediate access to over 100 highly accurate and actionable metrics and 20 data dimensions - in real time and for deep retrospective analysis through historical reporting. There are dozens of built-in reports, and you can easily create your own reporting dashboards.

22%

OEE Improvement

M.H. | Plant Manager | Personal Care and Household ProductsAt Cosmetic Essence we have been aggressively working to improve our OEE and manufacturing efficiencies. So far this year, we have been able to achieve a 22% improvement in OEE, and Vorne XL has been an integral part of our improvement process. By knowing the status of all our lines in real-time, we can address problems in real-time. With XL, our entire team sees downtime, and eliminates downtime. We count on Vorne XL to show us what areas we need to address, and we take immediate action from there.

91.9%

Trial Conversion Rate

R.G. | Purchasing | Custom Envelope ManufacturerOnce people understood why it was important to the health of the company we not only saw a slight rise in our quality but productivity went up significantly. In addition to this, we also saw benefits we couldn't have imagined when we considered adding XL. The fact that we now know when we are stumbling on a job has helped to improve our quoting accuracy in a very tight market. The displays have also exposed training issues that we never knew existed. XL has helped us to maintain our quality-focus while improving many areas of our company.

99.5%

Count Data Collection Time Improvement

G.D. | Bindery Manager | High Volume Catalog PrinterHaving the data collected from the Vorne displays allows my supervisors to focus on machines that are running bad and to leave the good ones alone. The bottom line for us is that we cannot effectively react to what was done yesterday. Now, people on the line are always looking to see if their line is number one and do what it takes to make their line perform. No doubt we would not have the efficiency gains that we've achieved without the visuals. It used to take our supervisors 35 minutes to collect the count data for their 9 machines now they have it in 10 seconds!

24/7

Quality

D.S. | Manufacturing Engineer | International Printing GroupI have been very impressed with the displays from Vorne. I have worked with them since we installed them several years ago. Operating 24 hours a day seven days a week, we have never had a problem. We are used to dealing with machinery issues, but the displays from Vorne have NEVER failed. Day in day out they just work. We never hesitate to use Vorne in our plant. We don't mess around with quality here, and it's obvious Vorne shares our focus on producing a quality product.

100% ROI

In One Month

J.N. | Web Press Manager | Commercial Printing CompanyInitially we did not know how much of a difference XL would make… It has raised production undoubtedly and we plan to use the display in all of our hot spots this year… Great product, it paid for itself in a month.

29%

Production Efficiency Increase

R.H. | Engineer | Large Print Advertising CompanyWe saw an immediate 29% improvement in production efficiencies just by adding Vorne displays! The project has been so successful that we've now outfitted two complete plants with XLs and are working on another. Corporate is so excited about the project that they've approved the budget to do every plant we have in the next year.

33.3%

OEE Improvement

D.G. | Operations Manager | Grain Milling and Packaging CompanyAfter we installed and deployed the Vorne XL Productivity Appliances we analyzed the data, and started understanding our underlying issues. We benchmarked our primary line and recorded an OEE Score of 45%. When we felt we had a good idea of what was going on, we started working to improve our productivity. We use OEE as the primary metric to gauge our progress. XL gave us the tools to track and eliminate our downtime, and improve our productivity. 10 weeks later we are hitting 60% OEE and still making improvements! Of our 10 best shifts of all time, 5 occurred in the last 30 days. Vorne XLs have been key to improving our productivity.

Over 100%

Of Target

C.P. | Lean Coordinator | Global Aluminum Products ManufacturerWe absolutely love XL! We show our monthly goal and what has actually been produced. As a matter of fact, last month we beat our production goal. The Vorne display played a significant role in our ‘win’ because it helps us to keep everyone focused on what needs to be done. What a great tool!

22% Improvement

In OEE During Free Trial

Pascal Bourdages | Plant Manager | NovatechWe have XL on a 90-day trial and have already seen a 22% improvement in our OEE score. We are keeping our trial unit and will be adding our next unit shortly!

94%

Downtime Reduction

S.T. | Plant Engineer | International Glass Products ManufacturerThe Vorne displays definitely generate a competitive interest on the plant floor. Until we put the displays up it was not uncommon to see 160 minutes of shift downtime. Now that operators can see the downtime in real time it is down to just 10 or 12 minutes per shift. Also, one of our production shifts just broke the all-time run rate for the line.

22%

OEE Improvement

91.9%

Trial Conversion Rate

Pulp and Paper Manufacturing

Driving Improvement for Pulp and Paper Manufacturing

Key Benefits for Pulp and Paper Manufacturers

You're In Excellent Company

Learn More About Vorne XL

Metrics, Dimensions, and Dashboards

Vorne XL User Success Stories

Pulp and Paper Manufacturing Specialties