The Importance of Refresher Training

“Since we completed the ‘super user’ refresher training with the customer on their Escada Profile process control system, they reported zero customer complaints about warp within the first month,” says Craig Tait, Managing Director of ePS Escada. “But like any new system installation, it is important that a plant maintains momentum and engages with the supplier to ensure all aspects of a system are working well and that operators are happy with everything, including how best to maximize the system and their investment.”

Craig adds: “What was interesting was that average production speeds have increased since we completed the ‘super user’ sessions. Smurfit Westrock Fishergate now wants to engage in further sessions to cover more users, which is encouraging. This is just one example of a customer prepared to invest in its people and effectively engage with its suppliers.”

Scott McKail, Production Supervisor at Smurfit Westrock Fishergate, comments: “Since the tailored remote super user training conducted for us here at Fishergate by one of the ePS Escada Process experts, we have seen an instant improvement in board quality and a reduction in customer complaints, especially for warped board, which has always been our biggest cause of returned board.

“During the training, the ePS Escada Process expert helped us develop a more efficient run style for our corrugator by reducing all heat settings in the hotbeds and triple stack preheaters. Since this was changed, we saw a big improvement in all grades and did not have a single warp complaint for over three weeks, which has never happened here before. The biggest benefit we’ve noticed is that all supervisors, shift managers, and wet-end operators have a much better understanding of how the system works and the importance of maintaining sensors so we have accurate readings at all times.”

More Training Wanted

The success of the refresher training led to a steady improvement in line speeds. As the team better understood the benefits of using features like cruise control, which had previously been underutilized, they saw an overall increase in production speed.

“We have also seen a steady improvement in line speeds as the supervisors understand the importance and benefits of running with cruise control turned on, which wasn’t happening before the training,” says McKail. “The production line speed has seen an overall improvement so far this year. Due to the benefits and results we have seen from people receiving this training, we will organize more courses with ePS for further improvements that we can implement.”