Improving paper production efficiency through integrated planning

A paper manufacturer worked with LTPlabs to connect production scheduling decisions across paper machines and converting operations. Preliminary comparisons showed higher effective production rates and less setup time per ton, while validation continue.

The challenge

The manufacturer’s planners determined production sequences largely through experience. They had limited means to compare the effects of different decisions about which orders to produce, how to group paper grades and where to allocate work across machines.

Those decisions are closely connected. Switching between paper grades can require setup time that reduces available production capacity. Plans must also account for maintenance, machine specifications, material availability and target dispatch dates. The company needed a way to evaluate these constraints together while allowing planners to review and adjust the proposed plans.

The solution

LTPlabs developed a customized application that links the main stages of the planning process. Planners select orders and define a production scenario. Optimization models then determine paper making needs, sequence work on paper machines, create finishing orders and sequence converting operations. The application presents proposed plans and performance indicators for planner review.

The models reflect operational requirements documented with the planning teams. Paper machine sequencing considers maintenance periods, grade transition rules and production goals. Converting sequences account for material availability, machine constraints and setup times that depend on the order of jobs. Planners can adjust parameters and review the effect of proposed sequences before confirming a plan.

The new planning application is currently being adopted, and its actual results are being measured. Other planning components and integration with the manufacturer’s production system remained in validation.

Results

Preliminary comparisons covered four planning weeks at one mill. The proposed plans increased the effective production rate by approximately 1.8 percentage points, from an already high baseline above 90%, while reducing setup time per ton produced by approximately 45%. These improvements were achieved without negatively impacting service levels.

For specialized printing paper, the proposed plans increased the effective production rate by approximately 2.3 percentage points, while reducing setup time per ton produced by approximately 51%, with the service level remaining broadly stable.

These preliminary results support the potential of the proposed methodology to improve planning efficiency. Final validation is now under way as the plans are progressively implemented in the production environment.