Paper industry

Solution implemented and results achieved:

• The possibility of controlling and supervising an extensive paper production line was introduced,
• Screens for accessing real-time and archival data directly on paper units were prepared,
• A detailed insight into the history of each parameter has been designed thanks to the Proficy Historian industrial database,
• Control of availability of paper units was obtained – by determining OEE indicator.

Benefits for the Customer:

• Enables the identification of the OEE indicator – availability of units
• Limits losses between operations
• Enables clear generation of reports for the selected period with the determination of reasons for downtime
• Enables a quick response in order to maintain continuity of production when a failure occurs
• Enables an objective assessment of the quality of the modernizations carried out as well as of the impact of the changes introduced within a unit

Solution implemented and results achieved:

• Expansion of the raw material consumption tracking module (folding and rolling processing),
• Import of production orders and BOMs from the ERP system,
• Implementation of a mechanism for generating batch numbers and a mechanism for counting downtimes,
• Expansion of the mechanism scanning bar codes to retrieve information about raw materials (components) used in production.

Benefits for the Customer:

• The integration of MES Plant Applications with ERP and WMS systems provides extensive capabilities for the analysis of production genealogy – from the paper machine to the machine packing the products into unit packages,
• The link between a production batch code and a WMS bulk pallet ID ensures precise reporting in case a batch needs to be withdrawn from the market or in case of a complaint,
• Reduction of the reporting and search time from a few hours to a few minutes, thanks to the new reports.

Solution implemented and results achieved:

• New open SCADA and Historian platform provided,
• Possibility of proactive maintenance,
• Programmed algorithm analyzing production.

Benefits for the Customer:

• Detailed information on wear and durability of saws and support for the Maintenance Department,
• Possibility to analyze the rate of saw blade wear as a function of subsequent sharpening,
• Greater control of production and machinery thanks to information on cut lengths for each order,
• Elimination of manual production reporting – integration with PLCs to ensure 100% data integrity and correctness,
• Access to unambiguous supervisory data for any given period in the form of a report.

Solution implemented and results achieved:

• Software audit
• Optimization of server redundancy configuration
• Optimization and configuration of communication protocols
• Basic and advanced training for workers

Benefits for the Customer:

• Increase in system reliability through the optimization of settings
• Improvement in communication with PLCs, monitoring connection statuses
• Increasing crew competence in the scope of operating and programming SCADA systems
• Faster response to failures and unforeseen situations.