Mondi Heerlen is part of Mondi, a global leader in the sustainable paper and packaging industry. Their facility specializes in producing release liner, a crucial component in the manufacturing of feminine hygiene products and other applications.
The challenge
Two key objectives drove Mondi Heerlen’s production department: faster training and reduced unplanned downtime.
Recent years had seen experienced operators either retiring or moving to different positions. While their replacements were highly motivated, they lacked the same level of experience. This created an urgent need for quick and efficient knowledge transfer.
After witnessing an ELICIT Online demonstration, Mondi decided to initiate a pilot project with the platform.
The ELICIT Online solution
ELICIT Online collaborated with Mondi Heerlen to develop a comprehensive knowledge file for their coaters – machines that apply adhesive to large paper rolls. These machines are particularly complex because various product qualities are closely interconnected.
The knowledge file captured this interplay, providing operators with enhanced understanding of their actions’ effects. As Operations Manager Guy Vlecken explains: “When a malfunction occurs, it’s crucial for operators to understand what’s happening and identify the root cause.”
The knowledge file has improved operators’ decision-making capabilities, particularly when working with different coating types.
Implementation process
The knowledge compilation began with interviews conducted by Bauke, ELICIT Online’s knowledge analyst, who spoke with various Mondi Heerlen colleagues.
Werner Wetzels, Production Trainer at Mondi Heerlen, now maintains the knowledge file independently. He particularly appreciates the system’s user-friendliness: “I observe operators frequently using the software. They can easily locate the information they need.”
Previously, troubleshooting required operators to search for information away from their workstation. Now, all necessary information is accessible right at the production line. “Having quick and easy access to information beside the line is a tremendous advantage,” notes Wetzels.
The production team’s positive experience with ELICIT Online led to the initiation of two additional knowledge files for other machines during the pilot phase.
Results and benefits
The implementation has delivered several key improvements:
- Employees and new hires now have a clearer process overview through the knowledge file
- The user-friendly platform facilitates efficient knowledge recording and sharing
- Training time for new employees has decreased significantly
- The facility has achieved reduced unplanned downtime
- These improvements have resulted in substantial time and cost savings
Through ELICIT Online, Mondi Heerlen has successfully addressed their initial challenges while creating a foundation for continued operational excellence.
Relevant cases
When the master leaves: how CONO preserves half a century of cheese-making expertise
The retirement of team leader Pieter (50.5 years of experience) confronted cheese producer CONO with a major challenge: how do we ensure that the knowledge of such experienced people is retained? Arthur van Esveld, Production Manager, and Mike Koster, the new Team Leader Cheese Production, explain: “With ELICIT, every operator has autonomy.”
Van Merksteijn: Less downtime
Van Merksteijn Fencing Systems ran into a number of problems in production. Breaking in new employees took a lot of time. Also, the training program for new employees was not available digitally. Another major pain point for Van Merksteijn was the lack of a uniform working method. In addition, employees have a lot of experience knowledge, but it was not recorded anywhere. That knowledge was in danger of being lost when they retired. Finally, operators were dependent on other, more experienced colleagues for breakdowns and other problems. That cost time, and therefore money.
Lemoine: Operators in control
Lemoine Holland is part of the Lemoine group and specializes in hygiene products. A common challenge faced by Lemoine Holland in Emst: How do I get my operators to the level where they know what, how and when to adjust?
Burg Azijn safeguards the expertise of master brewers and standardizes natural vinegar production.
The refined production process of natural vinegar at Burg Azijn (part of the Burg Group) used to exist mainly in the minds of a small group of master brewers. With the help of ELICIT, they reduce their dependence on specialists and achieve consistently high quality through a standardized approach.
Ten Cate: Investing in efficiency and in people
The company has gone through an ambitious growth program. A large-scale improvement process with a desired output: higher delivery reliability, higher output and a more consistent product quality. In order to achieve this, better training and a higher level of knowledge among the operators is necessary. That meant only one thing: investing in efficiency and in people.
Sharing knowledge is in our DNA
