Resolute Forest Products
Resolute Forest Products is a global leader in the forest products industry with a diverse range of products, including newsprint, specialty papers, tissue, market pulp and wood products. The company owns or operates over 40 pulp, paper, tissue and wood products facilities in the United States, Canada and South Korea, as well as power generation assets in Canada.
Marketing its products in close to 80 countries, Resolute has third-party certified 100% of its managed woodlands to internationally recognized sustainable forest management standards. Resolute’s portfolio of commercial printing papers includes a wide spectrum of coated and uncoated mechanical papers that offer an attractive solution for practically any commercial printing application. With mills strategically situated to serve major markets throughout North America and abroad, Resolute is a leading global producer of top-quality newsprint.
Resolute’s Fairmont Mill is one of two mills in US that produces recycled bleached kraft pulp and was recently awarded the Resolute Board of Directors’ Safety Award for 2014 for the most hours without a recordable injury.
The Adams Strategy Group served as Resolute’s primary operational excellence system architect and head coach through their cultural transformation stage. Adams Strategy Group connected at the senior team and internal continuous improvement team levels.
Operational Excellence Director, Daryl Pogue says this, “ Let me begin by stating that our OE journey has already taken us through a few bumpy times, and yet has been grasped and retained by our employees. One example was an early time in our journey when our mill was shut down for a period of 44 days due to market related conditions. Our Steering Committee at the time decided we wouldn’t push OE as many of our hourly workers were the ones who were home and drawing low-earnings checks. However, on the second day of returning to work, our hourly employees are the ones who circled the wagons and called everyone back together for their Daily Meetings at their Balanced Scorecard, in order to set their plans on how we were going to start this mill up after being down so long! They immediately started turning in Improvements, they were asking for their safety audit sheets and got back on-task like they were not going to let another outage happen like that again. Following this example, we as the Steering Committee, got it together by the third day!”
Pogue comments on their internal Innovation (Suggestion) System: “We call our suggestion system our Improvement System. We began in one department during July 2011, a second department the next month, and spread it to the rest of the mill by September 2011. Within the first year we had over 1,000 Improvements! A lot of low-hanging fruit was recognized that first year, with safety right up there near the top. Since we began four years ago, total ideas implemented have been over 1,600 Improvements. Employee participation rates have been: 2011- 34%, 2012- 48%, 2013- 57%, 2014- 67%, 2015 to date- 63%. The first couple of years, the Improvement System is an individual system. But we introduced and began Team Improvements in 2014. We had eight team improvements implemented that year, two of which were cross-functional teams of differing departments- we hadn’t even counted on that until it happened! 2015 to date has had 18 Team Improvements, and nearly half of them are cross-functional! Amazing!”
Pogue goes on about the mill’s incredible safety record, “On our BSCs (balanced scorecards), Safety is our first priority. We as a mill in the past have stated this and previously our focus was on lost-time events. And yet we were still hurting people AND budgeted annually for getting people hurt. No longer! It has now been over 2 years and over 500,000 Man-hours since our last OSHA Recordable. And IF we would have properly problem-solved the issue that led up to our last recordable, we could have another 3 or 4 months over that! This accomplishment is a record for this mill; each and every day we are not only adding to this achievement, but most importantly our employees are going home to their families safe, whole, and un-injured!”