A pulp and paper manufacturing process involves a number of machine and environmental parameters. One or two parameter drifting pushes quality out of band. Rule-based approaches cannot fully capture the complex patterns of operation that occur in this process. Even minor deviations from the norm can have a significant effect on product quality and machine utilization. Product quality may suffer due to suboptimal machine settings and lead to waste and even customer rejection.
Customer uses a distributed control system (DCS) integrated with human machine interface (HMI) software, as well as with planning systems. Customer’s team employs several process engineers who are well versed with the challenges of a 24x7x360 operation and aggressive production goals.
Customer’s DCS is integrated with Falkonry through an OPC-UA client, such as Kepware, that is able to send second-level granularity information about the process and environment. Falkonry assesses complex interactions affecting quality as seen in DCS data patterns in real-time as one of several conditions. Real-time classification of complex processes allows early detection of environmental or process changes affecting quality. Classification is relayed to process engineers who are able to intervene and perform targeted action with the knowledge of the named condition.
The integrated DCS – Falkonry solution enables early reaction to changes in production processes to result in tighter quality control, which in turn reduces customer rejection as well as material waste.