Proof of Concept

Like any investment proposal, the process has stages or steps to fulfill before final approval, or denial. Depending upon how robust that process is will determine the time to complete the process and the complexity of the steps to fulfillment

In this illustrative case the paper mill manager feels that if there is a vacuum transfer roll at the couch, picking up the sheet to transfer to the first press felt, threading time on paper breaks and during change of grades and weights, some 30 times per month on this lightweight printing & writing specialty machine.

This is a reliability improvement project.

A profit adding (PA) capital request was submitted and joined hundreds of other requests for funding in the multi-mill capital program. The initial request, a standard form with brief description of the issue, an even briefer description of the solution, estimates of capital costs and expected ROI are included.

The process involves a lot of ‘lobbying’, with management at the mill and above, and with engineering at the mill and above.

Receiving funding the first year is almost impossible, except for safety, environmental and ‘profit sustaining’ issues.

The nice thing about being a department manager, with P&L responsibility, is the authority implied in the maintenance work order process.

Write a work request, submit with personal contact and persuasion. Keep the total estimated costs within company dictated approval levels or, failing that, write multiple WR’s for various ‘phases’ of the project’s total cost, or something.

Avoiding central engineering and their potential questions, the mill’s maintenance engineer is assigned to assist with a proof of concept design and installation. He is eager, raring to go, turn him loose.

First the visit to the ‘boneyard’, a collection of pieces and parts removed, over the years, from throughout the mill, several paper machines, converting, pulp mill and power generation.

Lots of stuff, mostly reusable, especially for a throwaway proof of concept.

Let’s see, some wide flange I beam, channel iron, two air cylinders, air regulators, an motor, a discarded oversized felt roll, a regular sized felt roll, a uhle box.

Yep, we’ve got a plan and some scrounged equipment.

Spending some additional time beyond normal hours the ME designs the layout with guidance, review and approval of the paper mill manager.

The motor is mounted on the drive side journal of the oversized felt roll. It will win no design award.

The pieces are reconditioned, cut and shaped and assembled in the machine shop (roll grinding area).

Since this is a proof of concept the constructed arrangement looks like a ‘Rube Goldberg’ machine.

A planned shutdown allows the devices to be installed on the paper machine physically connected to the 1st press framing. The air cylinders, one tending side, one drive side, are activated and adjusted to work together lifting the oversized felt roll and the closely adjacent, attached uhle box, above the couch roll.

The reused motor connected through a gearbox spins the now felted arrangement to the desired speed closely matching the 1st felt speed, upon which the sheet, hopefully, will be deposited.

A crowd of spectators has gathered, Including the mill manager, the VP manufacturing, the director of corporate engineering and several of his engineers, most of the mechanics that worked on the installation and other interested bystanders.

The paper machine crew, e.g., machine tender, backtender, third through fifth hands and the paper mill manager begin the threading process. The paper mill manager, a hands-on leader, takes charge.

Time and time again, the sheet fails to transfer. The couch pit fills, needs to be diluted and pumped out. Many of the spectators wander off, losing interest.

Vacuum and speeds are adjusted, over and over, until, almost like magic the sheet transfers to the first felt.

The press section has a pulper. From there the machine is fully threaded wrapping the spool at the reel. The sheet is then expanded to a full reel.

Success.

The machine is shutdown the paraphernalia comprising the ‘homemade’ sheet transfer press is removed having proved it works.

Yes, proof the sheet can be transferred from the wire to the 1st felt, then through the 2nd and third presses, full width to the press section pulper, where the sheet is agitated, and stock is sent back to stock prep for recirculation.

The capital expenditure request is immediately approved, bypassing the typical 2-4 year ‘funneling’ process before approval for ‘profit adding’ requests.

Corporate engineering selects an OEM to design the new suction transfer press, a local mechanical contractor is selected to perform the installation. Mill crews will handle the electrical and instrumentation work required during installation. Corporate engineering will serve as project engineer/manager.

All this because the lightweight sheet running on this machine are troublesome with frequent web breaks further complicated because there is no storage in the couch pit causing excessive non-producing time on the machine for every wet end break.

More importantly perhaps, a learning experience for a young engineer incorporating multiple aspects of corporate life to which he will be exposed during his career.