Paper Mill Increases Order Fulfillment by 7.7% While Reducing Trim Loss by 12.3% Using Kaiznn AI
Haber deployed Kaiznn®, its AI-powered deckle optimization platform, to automate production planning for a paper mill managing highly customized customer orders. By intelligently optimizing deckle combinations in real time, Kaiznn increased order fulfillment, reduced trim loss, and enabled planners to generate optimized production schedules within minutes instead of hours.
The Challenge
Deckle matching is one of the most complex production planning activities in paper manufacturing. Most mills continue to rely on spreadsheet-based planning, where planners manually evaluate hundreds of possible order combinations to maximize machine utilization while minimizing trim waste.
The customer produced highly customized paper grades with continuously changing order quantities and delivery schedules. Manual planning created several operational challenges:
- High trim losses
- Lower order fulfillment
- Limited planning horizon (2–3 days)
- Long planning cycles
- Frequent replanning due to changing customer orders
- Lost production opportunities
Haber's Approach
Kaiznn consolidated customer orders, delivery commitments, inventory availability, machine constraints, and production specifications into a single planning environment.
Optimization algorithms evaluated thousands of possible deckle combinations to maximize order fulfillment while minimizing trim loss and reducing unnecessary production combinations.
As new orders entered the system, Kaiznn automatically recalculated deckle plans in real time, allowing planners to compare multiple optimized production scenarios within minutes.
Interactive dashboards provided real-time visibility into order status, production progress, inventory utilization, and planning performance, enabling faster and more informed production decisions.
Evidence-Backed Results
| Metric | Before | After | Change |
|---|---|---|---|
| Order fulfillment | 69.92% | 75.32% | 7.72% increase |
| Average Trim Loss | 3.26% | 2.86% | 12.29% reduction |
| Planning time | Several Hours | <30 Minutes | >95% faster |
Business Impact
Kaiznn transformed deckle planning from a manual spreadsheet exercise into an AI-driven optimization workflow.
Across 1,851 tonnes of planned production, the deployment delivered:
- 7.72% increase in customer order fulfillment
- 12.29% reduction in trim loss
- 101 tonnes of recoverable production
- Planning completed in 30 minutes instead of several hours
- Ability to compare multiple optimized production scenarios before execution
- Improved delivery reliability and machine utilization
Conclusion
Kaiznn enabled the mill to move from reactive, spreadsheet-based production planning to AI-driven deckle optimization. By continuously evaluating thousands of production combinations, the platform increased order fulfillment, reduced trim loss, shortened planning cycles, and unlocked significant production value without changing existing manufacturing assets.
