Recovery Boiler Instability and Reduced Production Capacity from Process Disturbances

$1.2M - $3.5M annually per organization (estimated on $50M revenue base): lost sales from stockouts, premium expediting costs from alternative mills (5-15% markup), excess inventory carrying costs, customer penalties for late delivery, churn from service failures • $120K-$320K annually (carrying costs of excess inventory, writeoff losses, opportunity cost of trapped capital, expedited logistics to correct shortages) • $150K-$400K annually (expedite surcharges, excess safety stock carrying costs, supplier penalties, missed volume discounts due to erratic ordering)

Manual collection of boiler efficiency metrics from control room; Excel tracking of energy KPIs; annual sustainability report compilation; email requests for boiler performance data • Manual daily stack monitoring; Excel tracking of emissions data; paper-based exceedance logs; manual reporting to regulators; reactive corrective action plans • Manual demand forecasting based on historical production; Excel-based supply planning; email/phone expedite requests to suppliers; safety stock overages to buffer instability