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Representative illustration: A specialty pulp and paper maker needed to cut waste, paper breaks and maintenance cost at one Midwest mill.

Case Study · Aerospace & Manufacturing

A specialty pulp and paper maker needed to cut waste, paper breaks and maintenance cost at one Midwest mill.

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1Challenge

Holes and contaminants caused unusable product and breaks. Equipment was uncalibrated, settings varied by shift, and preventive maintenance leaned on contractors and overtime.

2Approach

  • Set standard ranges and color-coded every gauge so operators could see in-spec status at a glance
  • Added a speed process monitor and split the daily report by shift for losses, breaks and uptime
  • Started a downtime kitting program so crews prepared parts for top work orders during shutdowns

3Results

$260K

Maintenance cost reduction

2

Planned shutdowns with less downtime

Shift-level

Visibility of loss, breaks and uptime

Less rework and waste, with a 24-hour maintenance cycle in progress.

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© USC Consulting Group 2026 | Aerospace & Manufacturing. Representative industry image. Results are engagement-specific; sizing and forecast figures are labeled as such.