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Magazine articles
Open Access
Leveraging mill-wide big data sets for process and quality i

Authors: Jianzhong Fu and Peter W. Hart | ABSTRACT: The MWV mill in Covington, VA, USA, experienced a long term trend of increasing episodes of paper indents that resulted in significant quantities of internal rejects and production downtime. When traditional troubleshooting techniques failed to resolve the problem, big data analysis techniques were employed to help deter-mine root causes of this negative and increasingly frequent situation. Nearly 6000 operating variables were selected for a deep dive, multi-year analysis after reviewing mill-wide process logs and 60000+ PI tags (data points) collected from one of the major data historian systems at the MWV Covington mill. Nine billion data points were collected from November 2011 to August 2014. Strategies and methods were developed to format, clean, classify, and sort the various data sets to compensate for process lag time and to align timestamps, as well as to rank potential causes or indicators. GE Intelligent Platforms software was employed to develop decision trees for root cause analysis. Insights and possible correlations that were previously invisible or ignored were obtained across the mill, from pulp-ing, bleaching, and chemical recovery to the papermaking process. Several findings led the mill to revise selected process targets and to reconsider a step change in the drying process. These changes have exhibited significant impacts on the mill’s product quality, cost, and market performance. Mill-wide communications of the identified results helped transform the findings into executable actions. Several projects were initiated.

Journal articles
Open Access
Digester thinning: Erosion-corrosion of internal flow channel headers, TAPPI JOURNAL August 2014

Digester thinning: Erosion-corrosion of internal flow channel headers, TAPPI JOURNAL August 2014

Journal articles
Open Access
Trends in pulp and paper mill emissions of SO2 and NOx, 1980-2010, TAPPI JOURNAL February 2014

Trends in pulp and paper mill emissions of SO2 and NOx, 1980-2010, TAPPI JOURNAL February 2014

Journal articles
Open Access
Editorial: Ricardo Santos: Applied Technology Specialist, TAPPI JOURNAL July 2014

Editorial: Ricardo Santos: Applied Technology Specialist, TAPPI JOURNAL July 2014

Journal articles
Open Access
Market projections of cellulose nanomaterial-enabled products - Part 2: Volume estimates, TAPPI JOURNAL June 2014

Market projections of cellulose nanomaterial-enabled products - Part 2: Volume estimates, TAPPI JOURNAL June 2014

Journal articles
Open Access
Editorial: TJ editorial board members review 2013 PEERS, IBBC and Research Forum on Recycling, TAPPI JOURNAL September 2013

Editorial: TJ editorial board members review 2013 PEERS, IBBC and Research Forum on Recycling, TAPPI JOURNAL September 2013

Journal articles
Open Access
Use of talc to control problems associated with dissolved and colloidal material in papermaking, TAPPI JOURNAL February 2012

Use of talc to control problems associated with dissolved and colloidal material in papermaking, TAPPI JOURNAL February 2012

Journal articles
Open Access
Press Drying, The Hydra-Nip Dryer: the easy way to surface smoothness, September 1998 TAPPI Journal, 88SEP73

The Hydra-Nip dryer: the easy way to surface smoothness, TAPPI JOURNAL September 1988

Journal articles
Open Access
The effects of chip blending of Pinus radiata kraft pulp, September 1988 TAPPI Journal 88SEP89

The effect of chip blending on Pinus radiata kraft pulp, TAPPI JOURNAL September 1988

Journal articles
Open Access
Dryer Fabrics Cleaning: a way to reduce steam consumption and improve sheet quality, September 1988, TAPPI Journal 88SEP97

Dryer fabric cleaning: a way to reduce steam consumption and improve sheet quality, TAPPI JOURNAL September 1988

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