Industrie 4.0 Papermaking 4 - gernsbacher-meister.de › images › Vorträge... · Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 Voith in figures 2 1867 €4.25 billion

Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 1

Industrie 4.0 – Papermaking 4.0 Gernsbach, 2017-05-19

Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19

Voith in figures

2

1867 €4.25 billion

Sales

5 Markets

19,000 Employees

60 In more than

4.9 %

R&D ratio Family-owned since

countries

Stand: 2015/16


Energy A quarter of all electricity generated

by hydro power worldwide is produced with

technologies and services from Voith.


Oil and Gas Voith offers reliable and efficient technologies and

services to the oil and gas industry for extracting,

transporting and processing these raw materials.


Paper Technologies from Voith are used in all sectors of the

paper industry. A large proportion of the world’s paper

is produced on Voith paper machines.


Raw Materials Couplings, gearboxes and many other Voith

components contribute to the constant availability

of raw materials for industrial processes.


Transport and Automotive

Voith is one of the leading suppliers of mobility technologies

and services in the transport and automotive market.

Voith is today one of the biggest

family-owned companies in Europe

Johann

Matthäus Voith

1803 – 1874

Friedrich Voith

1840 – 1913

Walther, Hermann

and Hanns Voith All shares are owned

by the Voith family

Management and

Supervisory Boards

are staffed by external

executives

Hanns Voith

1971 1867



The leitmotif for our daily work is: making our contribution today to the

society of tomorrow.

We serve global megatrends:

Urbanization, mobility, resource preservation and renewable energies

are the issues that will have a considerable impact over the coming

decades.

Agenda

10

Industrie 4.0 1

Papermaking 4.0 2


OnCare – Maintenance Solutions 3

4 Smart Services

OnEfficiency – Process Controls 5

Source: dpa Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 11

Information & Communication Technologies

for consumer markets

enter the industrial space


The four stages of the industrial revolution

First mechanical loom

1784

First production line,

Cincinnati slaughterhouse

1870

First programmable logic

controller Modicon 084

1969 4. Industrial revolution

(today)

3. Industrial revolution

(Early 1970s)


(End of 19th century)


(End of 18th century)

Industrie 4.0 3.0 2.0 1.0

CO

MP

LE

XIT

Y


Internet of Things: Focus on new business models and

services


Voith Digital Solutions


The Integration of Automation, Software, IT, Digitization,

Sensor- und Actuator Technologies, cyber-physical

Systems, Venture and Start-up Activities, Platforms and

Industrie 4.0

60 Countries

Global business activities in over

Voith Digital Solutions Global Presence

Planned Sales FY 2015/16

€ 380 Mio.

1,500 Estimated employees by end 2016

16

North

America Asia

Africa

Europe

Oceana South

America

Russia



OPRA SaaS

OPRA Project Solution

ERP NAV/ SAP/ Engineering/ Others

Security

VOITH Digital Customers

17

http://www.mwlbrasil.com.br/uk/home.html

http://www.johnsoncontrols.com.br/content/br/pt.html

http://www.daimler-tss.de/EN/index.html

http://www.al-ko.de/

http://www.wieland.de/internet/de/startseite.jsp

http://www.nikles.com/index.php/

http://www.fiducia-china.com/

http://www.schwenk-dt.de/

http://www.medag-stahlbau.de/cms/front_content.php

http://www.howden.com/de/

http://www.gmh-gruppe.de/de/startseite.html

http://www.kuka-robotics.com/germany/de/

http://www.rehau.de/index.shtml

http://www.vinnolit.com/vinnolit.nsf/id/DE_Home

http://www.hg-ct.com/index.php

http://www.heitec.de/index.php?id=1

http://www.ds-technologie.de/v4/startseite/index.php

Agenda

18

Industrie 4.0 1

Papermaking 4.0 2



4 Smart Services


Papermaking 4.0 targets Highest Productivity @ Lowest Cost

Time

Pa

pe

r in

du

str

y v

alu

e d

rive

rs

Productivity

Costs


Up to

10% higher Productivity

Targeted customer value.

Raising the Bar.

Break & Change time

50% less

Off-Spec Production

50% less

Unplanned

Downtime

50% less

ø


Energy

less

10%

Materials

less

10%

Labour

less

20%

Fibres

less

7%

Targeted customer value

Raising the Bar

Up to

10% lower

operating costs

8.5 M€ Savings*

88.7 M€/a*

Op. Cost

€

Maintenance Cost

10%

less

*example 300.000t/a B & P EU Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19


Global paper customer research

12 Countries Germany, Austria, Slovenia, Belgium,

Spain, Sweden, Finland, Turkey, China,

Indonesia, Australia, USA

30 Customers Customers really appreciate Voith’s

approach and notice Voith in a

different great way! They can’t wait to

see first products.

120 Interview Partners Mill Managers, Production Managers,

Maintenance Managers, Operators,

Automation Managers, Process Engineers,

Technology Managers 22


Realtime Data

Cockpits

Controls

Machine Monitoring

Simulation

Asset Management

...

Material Master Data

E-Documentation

E-Purchasing

Cockpits

Engineering Data

Smart Parts

...

Our strategic target - A digital twin in the cloud

Cloud

Local Voith Blue Box

(Edge Device)

Local Voith Blue Box

(Edge Device)

Cloud

Customer Supplier

23

What is Papermaking 4.0?


OnEfficiency: The modular solution to optimize

papermaking processes:

Visualize – Stabilize – Optimize.

OnCare: Intelligent condition based,

predictive maintenance

Self reflect – Implement – Improve.

SmartService: The service knowing your needs

What – Where – When.

IT Systems: IT infrastructure ensuring

reliable communication

and data secutity.

• CMS

• CMMS

• Diagnostics

• sensors

• controls

• actuators

• Analytics

• Remote

• Upgrades

Pm4.0

24

Agenda

25

Industrie 4.0 1

Papermaking 4.0 2



4 Smart Services


Well organized Maintenance provides

increased Safety, Reliability and Profitability


Would you like this car? or would you prefer this?

Both are 47 years old!

Bad Maintenance vs. Excellent Maintenance

26


Increase Productivity

• Avoid unplanned downtime

• Minimize planned downtime

Decrease Maintenance Cost

• Cost for labor & services

• Cost for parts & materials

The Challenge –

Two contradictory targets for the mill

27

The journey to Availability Excellence requires 3 things:

1. A change-minded and excellent team

2. Excellent processes and procedures

3. Excellent tools & services to support the transformation

How can Voith support and help:


OnCare MEx – high-end maintenance consulting

OnCare CM – next generation telemetric condition monitoring

OnCare AM – intelligent maintenance management system

Availability, how can we increase and sustain?

28

OnCare AM – All information and processes in one place


Wi-Fi

Object code: 200-030-010-050-010 PM02. Broke-Pulper 1. Agitator 2. Motor

OnCare AM – mobile solution


Local or Cloud

30

http://www.google.se/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjO3u3v1uXLAhVG2xoKHdRUB_MQjRwIBw&url=http://muristech.com/business-services/&psig=AFQjCNElV_VVWmuBG87jtqrPRVg3kcYQwg&ust=1459333426562008

http://www.google.se/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjO3u3v1uXLAhVG2xoKHdRUB_MQjRwIBw&url=http://muristech.com/business-services/&psig=AFQjCNElV_VVWmuBG87jtqrPRVg3kcYQwg&ust=1459333426562008

OnCare CM –

• imbedded in OnCare AM or standalone

• automatic generation of work orders notifications

• stationary & mobile

• mobile data evaluation IOS & Android

• Event tracking

• Technology monitoring

• remote expert support for condition and technology analyzes

• Modular concept – easy to roll out and expand


OnCare CM – state of the art condition monitoring

31

Navigation Mode

Inspection route including task

list and work order request

generation

Equipment view with

documents, maintenance

history and engineering data

Inspection Mode Inspection Route

Object status at a glance to

prevent redundant work order

requests

Arrow is showing route direction

Identifying and showing

hidden objects

Prepared for Voith Cloud database support in Papermaking 4.0

OnCare - Augmented Reality in Preventive Maintenance


OnCare MEx – Coaching of the “cultural change” program

implementation is essential

• Our Maintenance Management Experts will develop a customer

specific concept and coach the implementation.

• The level of support is defined by need and targeted

implementation time (18 to 60 month)

Lessons learned:

• internally driven cultural change processes are domed to fail

• develop internal experts to sustain (champions / ambassadors)


OnCare MEx - Implementation & organization

33

Comparison of Technical Data

Actions to reach the Target

• Maintenance Excellence with OnCare

Maintenance Excellence Content

• Implement best practices for shutdown planning & scheduling (MEx)

• Implement best practices for planning & scheduling, non-shutdown (MEx)

• Development of a risk based reliability maintenance program (MEx)

Maintenance cost optimization

Case study in North America

Before Target after 24 months

Machine uptime [%] 92 >95

Machine production [tpd] 820 >1,000

Machine speed at reel [fpm] 2100 3000

Maintenance cost [$/ton] 37 <27


cost optimum

OnCare Maintenance Excellence

Optimization Program

34

Agenda

35

Industrie 4.0 1

Papermaking 4.0 2



4 Smart Services



Voith OnCall service family addresses all needs

Service Agreements

Single point of contact for all service requirements

Fast remote diagnosis / problem solving

Guaranteed response / on site time

Virtual presence on site

Automatic failure alarming


OnCall Video – Virtual presence

Bring remote experts into the field

FROM HERE When help is needed at the machine...

...you can get it

FROM HERE

OnCall Alert - Use case 1

Remote Maintenance Support

Local OnCare CM/AM installation

Critical Vibration level detected

Automatic notification to Voith

Evaluation of the Problem

Definition of criticality level

Decision on corrective measures

Creation of the work order

Feedback to local system


Agenda

39

Industrie 4.0 1

Papermaking 4.0 2



4 Smart Services


Tomorrow: A pivotal new level of transparency & controls.

Stabilizing processes to meet target KPIs.

Pro

ce

ss

flu

ctu

ati

on

s

Fluctuation Corridor

Stabilized Corridor

New Target Corridor

Time

Raw materials

People

Variance

of input

factors

Different

behavior of

individual PMs

High variance of

outputs, instable

processes

Rationally automated

stabilization

Equipment

Waste of resources


visualize stabilize optimize


OnE Cockpit: Easy-to-grasp Visualization

41

There is more than one way to produce the required quality


OnEfficiency Cockpit & Forming | Fajar Paper |

2014-07-23

A B

C

A detailed analysis of process data gave

that “C” is the most cost efficient way to

produce the targeted paper quality.

Target corridors for the Cockpit are

defined to follow “C”

OnEfficiency™ Cockpit

Turn data into information

• Key performance indicators

for technological processes

• Best practice corridors locally defined

• Realtime forecasts of offline measurements,

e.g. laboratory data

• For quick, reliable and consistent decision

making during operation

• As tool to facilitate the audit and line

optimization


Define Target corridors for hundreds of tags


Semi-automatic Limit definition

• Automated limit detection for given

signal length

• Up to 3 time periods in parallel

• Technological limit

acknowledgement required

• Find the “C” way for all process

KPIs

44

Performance overview from pulper to reel


Fast overview over the entire

process.

Immediate information when

deviations from normal occur

No unnoticed process

fluctuations

45

Reduction of Complexity

13 Detail pages instead of 400


Entire DCS / QCS / Lab Data

Process, Chemical Prep & Quality

46

Data turned into Information!


Moisture Size Press:

• Is on target at the moment

• Was above upper limits and almost

below lower limit in the past 4 hours

• Is changing fast and will be too low in

4 hours if nothing is done.

47

Virtual Sensors

Use data to optimize the process!



Good reasons for Virtual Sensors

In real applications, many process variables cannot be

measured online, since

• Areas are not accessible for sensors

• Sensors would be too expensive

• Evaluation of sample in laboratory results in large time

delays

Remedy: Virtual Sensor combines paper process knowledge

with latest data analytic methods


Virtual Sensor

Real time measurement without “physical sensor”

Process Data

Machine Data

Quality and Lab. Data

Physical Model

∑

𝑓(𝑥)

Statistical Model

Virtual Sensor

Operation

Advanced Control

Visualization

The virtual sensor of a testliner machine predicts lab values for

Burst.


Burst

Number of measurement 3336

Timeframe 2016-05 to 2016-11

R² correlation P1 0.94

Number of parameters 20

Performance of the model

Typical accuracy: 98 out of

100 values are within ±5 %

of the measuring value

51


VirtualSensors Strength & Porosity

Results

Mullen

STFI

porosity


Chapter Divider with Example Image, Arial 40 pt Voith Blue

OnEfficiency Controls

53

How does it work?

Domain Knowledge meets Automation & IT


Process Step 1

Process Step 2

Process Step 3

Quality Target

€ for

Quality

Multiple Process Steps

contribute to a quality target

Create process step CPS

with performance self

awareness

€ for

Quality

€ for

Quality

Use domain knowledge Technological

Limits

Technological

Limits

Technological

Limits

Cost based coordination Real time optimizer or model predictive control

Quality at

Minimum

Cost

54


OnEfficiency Strength

Realtime Adjustment of Strength

on Board & Packaging machines

OnEfficiency Strength Lay out for double ply board 450.000 tons p.a.


OnEfficiency - Mondi Group | J. Flitsch | 2015-03-10

Dry line

control

Furnish ratio

control

OnE Cost Manager

Strength

Control

Refiner

control

Start up: Aug/Sept. 2015

J/W BW

Start up: Feb. 2016

Virtual STFI

Mullen

56


Dry Content (FormingSens)

OCC Ratio

Slice Lip

Wire Speed

Basis Weight

Refiner Load

Former Vacuum

Manual operation Automatic control

Field results: OnEfficiency Dry Line Control

Double ply board, 450.000 tpy Dewatering Control

• Dry line stable

despite changes in

-refining

-dewatering

-lip sclie opening

• Less energy costs

More constant quality

paper production

Field results B & P: OnE Strength

Double ply board, 450.000 tons per yr, February 2016

Jet/wire ratio

Dry weight

OnEfficiency strength active Manual control


STFI Min spec. 28.4

1.5#

Results

• Basis weight set point

reduced from 55# to

53.5# (-20 tons/d fiber)

• Fiber savings 20

tons/d

• J/W ratio from 30ft to

40ft

• STFI stable on

preselected setpoints


OnEfficiency DIP

Realtime Adjustment of Product Quality

in Deinking Stock Preparation

OnE DIP

Advanced DIP Process Control


Set Point Brightness

Ash sensor

Brightness sensor

OnE

Yield

VOITH

OnE

Bleach

VOITH

Set Point Ash

OnE

Yield

VOITH

OnE

Bleach

VOITH

Set Point Ash Set Point Brightness

OnE

DIP

VOITH

Resources prices

Final Set Point

• Ash

• Brightness

60

26

22

3

2

7

6

2

2

0

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

36

38

40

42

1 1

Status Audit OnE DIP

41

32

Case Study: OnE DIP Mill, 350.000 T/y, Europe


Savings/year

Yield (ash balance) 1.54 Mio€

Energy flotation pumps 0.37 Mio€

Chemicals/Additives 1.24 Mio€

Faster grade change 0.40 Mio€

Total

3.55 Mio€/year

OnE

DIP

VOITH

Process Audit OnE DIP Rebuild Technology

Services

Losses

Flotation pumps

Hydrosulfite

Peroxide

CaCO3

Co

sts

(€

/T)

61

Step 4

The future state is

maintained and further

tuned through

continuous monitoring,

maintenence and

optimisation

Preservation

The process & plant

performance is optimised

into the future state and

continuously monitored

and controlled to maintain

Optimisation

The continuous

visualisation & monitoring

of process performance &

plant condition is

established to determine

current state.

Visualisation

The current state is

stabilised through

removal of process

fluctuations and

equipment reliability

improvements.

Stabilisation

OnCall Remote & On-Site Service

Step 3

Step 1

Step 2

Step 4

Value add assessment

The Papermaking 4.0 methodical approach

Contact:

Jürgen Käser

Head of Efficiency Solutions

Tel. 0751 83-3541

[email protected]


Documents

Industrie 4.0 Papermaking 4 - gernsbacher-meister.de › images › Vorträge... · Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 Voith in figures 2 1867 €4.25 billion