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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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 3
Energy A quarter of all electricity generated
by hydro power worldwide is produced with
technologies and services from Voith.
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 4
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.
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 5
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.
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 6
Raw Materials Couplings, gearboxes and many other Voith
components contribute to the constant availability
of raw materials for industrial processes.
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 7
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 8
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 9
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 12
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)
2. Industrial revolution
(End of 19th century)
1. Industrial revolution
(End of 18th century)
Industrie 4.0 3.0 2.0 1.0
CO
MP
LE
XIT
Y
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 13
Internet of Things: Focus on new business models and
services
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 14
Voith Digital Solutions
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 15
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
OPRA SaaS
OPRA Project Solution
ERP NAV/ SAP/ Engineering/ Others
Security
VOITH Digital Customers
17
Agenda
18
Industrie 4.0 1
Papermaking 4.0 2
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
OnCare – Maintenance Solutions 3
4 Smart Services
OnEfficiency – Process Controls 5
Papermaking 4.0 targets Highest Productivity @ Lowest Cost
Time
Pa
pe
r in
du
str
y v
alu
e d
rive
rs
Productivity
Costs
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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?
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
OnCare – Maintenance Solutions 3
4 Smart Services
OnEfficiency – Process Controls 5
Well organized Maintenance provides
increased Safety, Reliability and Profitability
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
Would you like this car? or would you prefer this?
Both are 47 years old!
Bad Maintenance vs. Excellent Maintenance
26
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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:
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
Wi-Fi
Object code: 200-030-010-050-010 PM02. Broke-Pulper 1. Agitator 2. Motor
OnCare AM – mobile solution
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
Local or Cloud
30
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 32
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)
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
cost optimum
OnCare Maintenance Excellence
Optimization Program
34
Agenda
35
Industrie 4.0 1
Papermaking 4.0 2
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
OnCare – Maintenance Solutions 3
4 Smart Services
OnEfficiency – Process Controls 5
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 36
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 37
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 38
Agenda
39
Industrie 4.0 1
Papermaking 4.0 2
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
OnCare – Maintenance Solutions 3
4 Smart Services
OnEfficiency – Process Controls 5
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
visualize stabilize optimize
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
OnE Cockpit: Easy-to-grasp Visualization
41
There is more than one way to produce the required quality
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 43
Define Target corridors for hundreds of tags
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
Entire DCS / QCS / Lab Data
Process, Chemical Prep & Quality
46
Data turned into Information!
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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!
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 48
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 49
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 50
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.
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 52
VirtualSensors Strength & Porosity
Results
Mullen
STFI
porosity
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
Chapter Divider with Example Image, Arial 40 pt Voith Blue
OnEfficiency Controls
53
How does it work?
Domain Knowledge meets Automation & IT
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
OnEfficiency Strength
Realtime Adjustment of Strength
on Board & Packaging machines
OnEfficiency Strength Lay out for double ply board 450.000 tons p.a.
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
OnEfficiency DIP
Realtime Adjustment of Product Quality
in Deinking Stock Preparation
OnE DIP
Advanced DIP Process Control
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19
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
juergen.kaeser@voith.com
Gernsbach | Industrie 4.0 | Papermaking 4.0 | 2017-05-19 63
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