Sometimes the biggest process wins come from the smallest fixes nobody was looking at.
At the DDL/Decker Washer Section, restricted water flow was silently killing washing efficiency. Scale was building up inside the pipeline, choking pressure, and making the entire washing process unstable. Nobody had a permanent fix in place.
Abhishek Singh and the team decided to actually get to the root of it.
What was really going on
When operations shifted to ODL, the seal tank backwater line had zero antiscalant dosing. The result was rapid scale buildup inside the mild steel pipeline, dropping spray pressure and making washing performance unpredictable.
What they did
The team dismantled the affected pipeline, physically removed the scale buildup, and then coordinated with the chemical supplier to deploy a continuous antiscalant dosing system on the ODL seal tank backwater line so the problem could never quietly come back.
The result
Pipeline cleaned. Flow restored. Pressure normalised. And a continuous dosing system now running proactively to stop scale from ever coming back.
Frequent choking, gone. Process upsets, eliminated. Pulp washing, back to optimal.
This is what good kaizen looks like. Not a dramatic overhaul. Just a sharp team, a real root cause, and a fix that actually lasts.