ditp bled symposium 2017 the best in class mill operations

November 22, 2017 Slide 1

DITP BLED SYMPOSIUM 2017

The Best in Class Mill Operations

Mikko Jalava, Sales Director CPM

Industrial markets poised for massive value migration


A $4 – 11 trillion digital opportunity by 2025

Internet of Things

Mobile internet

Automation of knowledgework

Cloud technology

Advanced robotics

1

2

3

4

5

Pulp and Paper

1.7 – 6.2

5.2 – 6.7

Level ofDigitalization

Economic impact of most significant technologies

1.7 – 4.5

3.7 – 10.8

3.9 – 11.1

$ trillions annuallyTime

CAPEX – based productivity levers are exhausted. Collaboration is the step tonext level productivity.

Why a new way of working?


Step 1: Automate Step 2: Centralize Step 3: Collaborate

productivity baseline

Pro

duc

tivi

ty

+X% by automating(CAPEX investment)


Pro

duc

tivi

ty

+X% by centralizingand ERP

(CAPEX investment)


Pro

duc

tivi

ty

+X% by connectingexperts and data

(OPEX investment)

FieldInstrumentation

Electrical andDrive Systems

Extended Automation• System 800xA DCS System• QCS Quality Control System• WIS Web Inspection System• L&W Laboratory Systems and Devices

Collaborative Production ManagementcpmPlus for P&P

Collaborative Production Management for P&PUmbrella for ABB field instruments


Cloud based services

ABB Ability™: Pulp and Paper digital solutions

Unlocking the ABB potential in digital


Open access,intelligent cloud

Closing the loopwith connecteddevices

New end-to-enddigital solutions

Systems tomaster processcontrol

Paper MachineAnalytics

Energy Manager

ProductionManagement

Decision Support

Production PlanningOrder Management

OEE

Pulp Mill ProcessOptimization

Paper MachineProcess Optimization

PM (MMD) Wet End &Dry End Optimization

Liquor Line(OPT800)Optimization

Fiber Line(OPT800)Optimization

Vapor, Recovery,Soot, Lime, Caust

Cook, Wash, Oxygen,Bleach

Refiner, Blending, WetEnd, , MMD, AGC, MCD

ElectrificationIntegration controls

PM Drives(PMC800)Controls

Process ControlsDCS, QCS

HV/MV Electrification

Transformer,Switchgear, Relays

LV Drives and Motors

Automation andInstrumentation

Pulp &Paper Product

QCS, WIS, LabEquipment

cpmPlus Order ManagementAgility through full integration

Key Features:

- Order entry

- Capacity and warehouse levelchecks

- Order confirmation, invoicing andcomplaint handling

- Automatically generates orderconfirmations, sales documents,invoices etc.

Key Customer Values:

- Complete integration with othercpmPlus products offer full visibilityto planning, production, delivery,warehousing and delivery planningà eliminates need for dataexchange interfaces

- Capacity check & profitabilitychecks for the sales personnel



cpmPlus Order ManagementOrder Entry

Enter sales officeand customer and

default data isupdated

automatically

Order line display

Order items areselected from ready

made lists withdefault values

ATP = available topromise

CTP = capacity topromise

ATP/CTP allow to seeavailable stock,

production capacity

cpmPlus Production PlanningOptimized production plans

Key Features:

Scheduling tool:- Used for production scheduling- Automatic or manual block scheduling- Capacity tools, simulation possibility, production time calculations

etc.

Trimming tool:- Trimming tool is used to create optimised production runs at

windersà 50% less trim waste compared to manual trimming

Re-trimming tool:- In a case of quality defect re-trimming tool can be used to remove

quality defect with minimum amount of waste.


- Minimizes delays and deviations from ordered quantities- Minimizes grade change costs and trim losses in all production

phases- Minimizes inventories, maximizes value of production- Multimill planning and optimisation, Profitable to Promise tool

(searches most economic mill to produce)- Cost function shows economic impact of schedule change


cpmPlus Production PlanningScheduling tool

Status of plannedorders and

availability ofproduction blocks

Uplanned orderswaiting to be

scheduled

Run schedule ofpapermachine

displayed in color-coded blocks

Color-coded blocksindicate free

capacity, overproduction, late

orders etc.

Status of eachplanned orders

cpmPlus Production PlanningTrimming tool

Jumbo roll trimmingplan per

customer/sheet sizeetc.

Trim loss perpercentage, moneyor tons is indicated

Trim optimisercalculates differenttrimming solutions

Over-/underproduction

per roll size

cpmPlus Quality ManagementComprehensive quality control

Key Features:

- Quality Manager collects all qualitymanagement data into one interface

- Allows user to follow quality of rawmaterials, semi-finished products andfinished products.

- Quality comparison and benchmarkingacross different sites


- Minimum quality losses

- Decreased reclamation costs

- Provides complete traceability

- Streamlines quality operations

- Visualizes and consolidates qualityrelated data from various sources


Laboratory Data QCS Data WIS DataProduct

specification/Customer

requirements

Optimized Trim(assume uniform quality)

Automatic re-classification based onmeasured quality and customer

requirements

White = A-qualityYellow = B-qualityRed = Reject

cpmPlus Quality ManagementComprehensive quality control


cpmPlus Quality ManagementJumbo roll quality map

Quality map ofjumbo shows

classification of eachroll

After PM user canmake re-trimmingplan or re-classify

rolls to reduce wastematerial. Re-

classification maymean selecting a

different customer,different grade or

accepting reject rollas B-quality.

Roll labels indicatecustomer and roll

dimension

Quality data and reeldata is available foreach individual roll

cpmPlus Production ManagementExecuting production plans optimally

Key Features:

- Production Management can beused to manage all manufacturingtransactions from raw materialmanagement, throughmanufacturing process to thewarehouse and finally to truckloading.


- Avoids under/ overproduction

- Reduces inventories (FG, WIP,materials)

- Ensures delivery on time - in full

- Provides full visibility to production

- Provides complete productgenealogy

- Provides on-line product costing

- Streamlines operations


cpmPlus Production ManagementPaper Machine Dry-end

Production hierarchytree for easynavigation

Run status showingplanned tons,

produced tons on PMand on Winder. Also

indication onrailstock, waste and

overproduction

Time display of PMproduction (no

transactions here)

List of last actionsfor active run

Status of eachplanned order

Navigation buttonsfor quality data

Navigation buttonsto classify events

cpmPlus Production ManagementWinder Station

Productioninformation: active

run, next sets,status…

Reel ID information

Navigation buttonsfor quality data

Planned rolls fromreel. Labels show ID,

dimensions andcustomer.

Color bars indicateproduction status.Green = produced.

Each roll can beclicked to see colormap, profile, defect

map etc.

cpmPlus Production ManagementSheeters

Run Status: pattern,sets, grammage,

product

Mounted rolls. Rollcan be clicked toopen roll specific

data.

Sheet size + actualproduction speed

Rolls waiting on floorstorage area.

Skids waiting to beregistered

cpmPlus History Process Data ManagementValue added applications for pulp and paper

Key Features:

- cpmPlus History is a database to store all processmeasurements as frequently as possible and as long asneeded.

- cpmPlus History is used to view, analyse and reportprocess information using it’s built-in applicationdevelopment tools.

- cpmPlus History is the foundation for many valueadded applications such as Energy Manager andcpmPlus OEE.

- Can be easily integrated to other systems (ERP, DCS)via direct interface.


- Fast, easy access database for all process data

- Creates full transparency in online process and historydata.

- Together with added application creates measureablevalue.


Interfaces

DCS

Lab

ERP or MES

Energy

Maintenance

ABB AbilityPlatform

Collaborative Operations provides ability to improve plant availability,performance, and quality

ABB AbilityTM Collaborative Operations

11/22/2017 Slide 19

ABB Collaborative Operations Centers

ABB AbilityTM Platform

Customer Operations Centers

EnergyOptimization Asset Health Safety

ManagementPredictive

MaintenanceEmission

MonitoringPerformanceOptimization

ConditionMonitoring

AlarmManagement

Analytics andVisualization Simulation Cyber

SecurityControlCenters

Operationsand Technical

Support

Analytics andVisualization

PerformanceOptimization

ConditionMonitoring

Collaboration in data-driven ecosystem


People make the difference

Collaborative OperationsEcosystem

Field devices

Data from devices like motors,drives etc. are gathered bysensors and transferred toEdge devices for analysis

Typical Pulp & Paper Mill:

50,000 connection points,10 TB’s of data’s / year40,000 I/O Control system,QCS, WIS and Lab Equipment,6000 LV Motor, 150 MV Motorand Motor Starters, 130Distribution Transformer andMV switchgear

Edge devices/ Fog

Advanced algorithms analyze dataautomatically and present actionableinsights for engineers at the mill level.

Data gets aggregated and analyzed in thecloud and is available to key stakeholders ofthe collaborative operations ecosystem sothey can make data driven businessdecisions

CollaborativeOperations

center

Web portal

CustomerApps, view installed

assets, viewoperations

ConsultantAnalysis, advanced

maintenance,operations

optimization

3rd partyAnalytics, services,generate solutions

ABB engineerRemote connection,update task list, live

monitor progress

ABB collaborationexpert

Root Cause Analysis,advanced services

ThingsServicesPeople


Follow-the-sun strategy for pulp and paper customers

Collaborative Operation Centers for Pulp and Paper

Westerville, USAWesterville, USA SingaporeSingaporeHelsinki,FinlandHelsinki,Finland

Collaborative Operations turns data into money at single plants and acrossenterprises

Leading solutions for ABB AbilityTM CollaborativeOperations


CustomerOperations

Center / HQ

ABBCollaborativeOperationsCenter

Customer assetse.g. rigs, mills, vessels

Analytics andVisualization

Simulation

Analytics

CyberSecurity

Cyber and safety

SafetyManagement

Operations andTechnical Support

AlarmManagement

EmissionMonitoring

EnergyOptimization

PerformanceOptimization

Optimization

Ops support Predictive maintenance

ConditionMonitoring

Asset Health PredictiveMaintenance

Control

ControlCenters

Increase Reliability

Improve Process Performance

Reducing quality variances

Productivity improvement

Digital technologies accelerate service delivery and value

Process Performance Improvement Digital Services

11/22/2017 Slide 23

Traditional Services Process Improvement Services Digital allows us to

Ensure availability

Avoid plant process disturbance

Control costs

Capture knowledge fast

Analyze data quickly

Improve performancecontinuously

ABB Ability for Pulp and Paper


Turning insights into actions

Fleet




Fleet Plant




Fleet Plant Machine




Fleet Plant Machine Control




Fleet Plant Machine Control Equipment

Paper Machine Performance QCS Sensor Performance

Benefits– Grade change improvement– Start-up time reduction

Expected business impact: 500 KUSD+ / year

Features

– OEE monitoring

– PM/Technical KPI optimization

– Daily performance check

– Action recommendation and execution


ABB AbilityTM Collaborative OperationsFeatures, Benefits & Business Impact

– Quality improvement– Sheet break reduction

Features

– Continuous analysis of Sensor KPIs

– Daily performance check

– On demand analysis

– Action recommendation and execution

Benefits

– Improved paper quality

Est. Business Impact: 200 KUSD+ /year

We Have Long History in CPMCreating value for our customers since 1975

ABB’s Experience in CPM for P&P:- First production tracking system 1975

- First energy management system 1978

- First quality management system 1982

- First trim optimization system 1982

- First production planning system 1993

Over 200 installed systems for Pulp and Paper

ABB is the marketleader in CPM forProcess Industries

ABB is the marketleader in CPM forProcess Industries



Thank You For Your Attention!

ditp bled symposium 2017 the best in class mill operations

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