Real-time Costing in Paper Mills Using the PI System...

© Copyright 2015 OSIsoft, LLC

Presented by

Real-time Costing in

Paper Mills Using the

PI System Infrastructure

Brad Anderson

Jon Evans


Verso Corporation

• Headquarters in Memphis, TN

• Leading producer of printing papers, specialty papers, and pulp

• 8 mills in Kentucky, Maine, Maryland, Michigan, Minnesota, and Wisconsin

• Annual production capacity of 3.6 million tons

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Luke Operations

• Manufacturing started in 1888 • Situated in 2 States and 3 Counties • 480,000 tons per year capacity • 2 Paper Machines • 4 Supercalenders • 4 Winders • 3 Sheeters • 800 Employees

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Triad of Managing Profitability

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Data Archive

Asset Framework

Event Frames

PROFITS

PR

OD

UC

TIO

N


The Problem

• Paper machine operators – No visibility into how actions affect

production cost

• Supervisors – No insight to indicate when paper

produced deviates from standard recipe

– End of month unfavorable variances in materials leads to time consuming search for answers

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The Solution • Data model using Asset Framework (AF) to track

component cost

• EFGen interface to create an Event Frame for each reel

• Cost roll up using Asset Analytics/Formula Reference

• PI ProcessBook displays for Operators with standard recipe values and deviations

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AF Template – Paper Machine

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© Copyright 2015 OSIsoft, LLC 8

AF Template - Component Cost


Grade Recipes and Components

Percentage of recipe ingredients


Event Frame Template

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Reel Production Framed as Events

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Center-lining “Cost” as Operator Variable

Operator Display ProVox

Operator Display ‘cost’ -PI ProcessBook


Operator Rounds

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Operator Rounds - PI Manual Logger – PC Data Entry

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Operator Rounds - PI Manual Logger – Tablet Data Entry

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• Operators have real time cost. Cost impact is visible as process changes are made

• Operations view material usage versus plan and not be surprised at the end of the month

• Controlling Cost in real time can reduce VC up to 4%

Solutions Results and Benefits

Summary Business Challenges

• Operators on the floor have no insight as to how their actions affect the cost of the product

• Operating supervision and finance do not have a convenient way to track material usage versus standard recipes during the month

• Leverage Asset Analytics in order to provide a window into real time costs

• Use Event Frames to monitor actual material usage by reel and grade

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“On a day to day basis the paper machine crews and supervision do not have any good way to determine their performance against the planned cost for each grade produced or to determine the effects of process changes to the overall production cost of the machine.

This costing tool provides that valuable information in real time so quick decisions can be made.”

Paper Area Manager


Brad Anderson

[email protected]

Applications Analyst

Verso Corporation

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Jon Evans

[email protected] IT Manager Verso Corporation

mailto:[email protected]

mailto:[email protected]


Questions

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Please wait for the microphone before asking your questions State your name & company


Date post:	06-Jun-2018
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Real-time Costing in Paper Mills Using the PI System...

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