POST

When Mark Rosebrock (Indy Field Service) received an urgent call before even arriving at the shop, he knew it was going to be a challenging day. A major paper plant in Ohio had been down for nearly a week, with Friday marking their last chance to get back online before the weekend. The situation was dire: their critical paper slitting machine, responsible for cutting 12 to 14-foot rolls of paper with a 7-foot diameter, had been out of operation for six days due to a persistent hydraulic issue. Despite replacing the leaking piston seal in the drive-side hydraulic cylinder, the problem persisted. With no repaired spare cylinder available, the plant faced the possibility of extended downtime. Horner quickly stepped in, with Mark heading to the plant to assess the situation. He identified a course of action, but encountered resistance from the plant’s facility maintenance group, who were hesitant to follow his recommendations. However, a corporate engineer on-site recognized the value in Mark’s approach and ensured his plan was executed. Despite the OEM representative offering little assistance, Mark and the corporate engineer forged ahead. Meanwhile, two technicians from a sister facility in Kentucky joined the effort, and together, they modified the PLC program to temporarily use the existing cylinder while repairs were underway. Through rigorous testing and careful execution, the team successfully brought the machine back online at a reduced speed to verify the solution. By Sunday, the machine was fully operational and handed back to the plant production staff. This swift, collaborative effort not only minimized the plant’s downtime but also demonstrated Horner’s capability to troubleshoot complex issues and provide rapid, effective solutions. The success of this project has solidified Horner’s reputation at the paper plant, paving the way for future opportunities to assist in maintaining and optimizing their operations.