alpha centauri project tm7 start-up€¦ · economy mainline premium. ... august 2016 internal...
TRANSCRIPT
Alpha Centauri project
TM7 start-up
Agenda
➢ Velvet Care Company presentation
➢ Alfa Centauri project aim
➢ Project execution
➢ Project routine
➢ Operator training
➢ Start-up
➢ Learning curve
➢ Key learnings
Over 120 years of history.
17 years as a part of international companies.
1897 Establishment of the paper factory in Klucze
1976 Activating of new paper machine #6
1996 Acquisition by International Paper
1997 Launch of Velvet brand
2003 Acquisition by Kimberly-Clark
2013 Acquisition by Avallon MBO II
01.08.2013 Formation of Velvet CARE
2013 Acquisition by ABRIS
120 years of Klucze mill history in 2017
Klucze mill established in 1897,
since then delivering products of
the highest quality.
Organizational structure / Board Members
Rafał Curyło
Finance Director – Member of the Board
In the company: 17 years
Business experience: 17 years
• CBU Modern Trade
• Business Analyst
Leader Central Europe
• Business Analyst Poland
• Controlling Specialist
Artur Pielak
General Manager – President of the Board
In the company: ca.5 years
Business experience: 21 years
• Hero PL/HU - General Mgr
• Nestle PL/BAL – Marketing Dir
• Gillette CEE – Bus Unit Mgr
• International Paper – Cat Mgr
• Unilever – Brand Mgr
Marcin Grabowski
Sales Director – Member of the Board
In the company: ca. 18 years
Business experience: 22 yrs
Prior experience:
• Cust. Bus. Manager MT
• Bus. Develop. Manager
• Regional Sales Manager
Marek Ściążko
Mill Manager – VP of the Board
In the company: 32 years
Business experience: 34 years
• K-C S.A. Poland – Mill Dir
• International Paper – Mill Dir.
• KZP Klucze – Mill Director
Operations/
LEAN
Logistics
Cust Service
Distribution
Quality, safety
and
environment
Mill
engineeringHR/Unions
Finance & IT
Marketing &
Category
management
Sales
Export &
Business
Development
Demand
Planing
We have ca. 570 Employees – majority experienced in Paper industry
Velvet Care – pillars of our strategy
PrivateLabels
DACH markets– strategic
partnership
Export
New categories
AwayFrom Home
VC NSV:
2014- NSV 40 mln EUR
2017- NSV 100 mln EUR
2020- NSV 150 mln EUR+
Velvet Care – investments in development
In the last 3 years we’ve upgraded existing and 5 new production lines, built high-tech warehouse and doubled or production capacity and turnover:
2014• upgrade of existing production lines
2015• technology of putting balsam on tissue and paper production lines • new production line for moist paper and wet wipes (1)• new production line for hanks tissues (3)
2016• new production line for facial tissues (2)• new production line for bath tissue (4)• new production line for Jumbo towel based on DESL technology (5)
2017• Opening of new finished product warehouse (6)
6
Velvet- synonym of tissue hygiene in Poland
Synonym of high quality… …appreciated by retailers… …and consumers.
Gold Medal
Quality Leader by Consumers
In all 4 categories
Complex product portfolio for each group of shoppers
Kitchen Towel
Facial tissue
Bath tissue
Economy Mainline Premium
Strong business in Private Label products
Alfta Cenaturi project aim
2018 is a year of the revolutionary change and the biggest investment in company development
• Activating of new tissue machine
• Another new production line for bath tissue
Business goals:• Strengthening Velvet Care position as an innovator and
creator of paper market in Poland• Further development in Private Label business• Export development• AFH business doubling 430mln
Project execution
➢ July 2016 final supplier TM definition
➢ August 2016 Internal Velvet Care Kick off meeting
➢ September 2016 Project Kick off meeting – 3 companies VC, Valmet and Building company
➢ December 2016 Layout drawings delivered by Valmet
Project execution
➢ March 2017 delay of Civil company required new project schedule. Original January 2018 start-up
was moved to March 2018. All companies were informed about delay
➢ Valmet and Iinstallation company schedule remain unchanged - the equipment was delivered
according original schedule. The installation company started during civil construction work.
➢ New flexible checkout process was established by Valmet
Time Basic Engineering Detailengineering
Manufacturing Civil design Civilexecution
Installation execution
Q1’17 100% 60% 20% 30% 5% 0%
Q’2 17 100% 75% 54% 40% 20% 0%
Q’3 17 100% 99% 91% 80% 60% 20%
Q4’17 100% 100% 100% 100% 98% 75%
Q1’18 100% 100% 100% 100% 99% 100%
Project routine
➢ Official report to the management board and financial institution – 1 x quarter
➢ Steering committee meeting – 1x month
– lead by VC project manager
➢ Civil company progress/decision meeting – 1 x week
– lead by VC civil project manager
➢ Installation company progress/decision meeting – 1 x week
– lead by VC process project manager
➢ Civil company operation daily meeting – Installation operational
daily meeting
- lead by Valmet Site Manager
➢ Daily startup meeting in control room
- lead by Valmet Site Manager
Training
➢ Q1 2017 – New process engineers (packaging paper background) joined the team
➢ Q2 2017 – Karlstad Valmet week training for process engineers and mechanical engineer
➢ September 2017 –new operational crew joined VC (only 4 people had papermaking experience,
moreover only one of them was TM leader)
Training steps
➢ Stage 1 The basic info for paper making processs. The crew had different trainer every day
(future leader of TM machine)
➢ Stage 2 – the teams were divided by job position (stock preparation team; refining team;
rewinder team) The training covered equipment and working procedure for each job position
➢ Stage 3 – practical activities during old TM6 annual shot down.
➢ Stage 4 – practical activities on old TM. The crew was TM6 employee shadows
➢ Stage 5 – Simulator class training. Basic DNA system information
➢ Stage 6 – Simulator problem solving
Training
The VC training program was finished in December 2017
Valmet training started in January 2018 and finished in March 2018
➢ Calss room training separately for stock preparation and TM
➢ Practical training – shadow of Valmet specialist during checkout time
➢ Start-up training – on working equipment
Alfa Centauri – Project start-up
➢ 02.03.2018 13:00 First reel on TM7 – BT 16,5 GSM
➢ 05.03.2018 Commissioning completion date (TM7 take – over). Signed certificate
➢ 12.03.2018 Project first preliminary production criteria confirmed more than 716 ton for 7 days
➢ April 2018 – first 180 t/ 24h was achieved ( 4 days above 170 t/24h production)
➢ May 2018 Project intermedia test was delivered ( 200 t/ 24h)
➢ July 2018 – first 2000 m/min speed was achieved ( only 4h production due to still LC on rewinder)
Project Learning curve
Time March April May June July August September
Plan 40% 50% 60% 70% 80% 90% 100%
Actual 65% 66% 66% 74% 85% 72% 88%
Project key learnings
➢ Reference visit is necessary to establish good business case for the project
➢ Clear common goals for all people and suppliers involved in the project
➢ Team working action (not only execution from suppliers but cooperation is required)
➢ Communication and face to face discussion – not only tele conference. The face to
face meetings are more effective, the communication flow is better, the clarification of
issue is better too.
➢ Focused on the issue not only on the contract scope
➢ Milestones definition and tracking process
➢ Training program is crucial
➢ Risk management – risk assessment in the project is necessary
Project key learnings after startup
➢ Checkout procedure is crucial and need time. Speed-up in checkout can cause longer start-up
(issues during the machine start because the system was not checked properly)
➢ Punch list after start-up need to be closed as soon as possible due to crew demotivation and bad
learnings.
➢ People solve the problems – key responsible contacts allow you solve your issue quicker
(Hans and Gunnar Thank you !!)
Civil movie - outside