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Magazine articles
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
Continuous Time Domain Characterization of Mixing in Agitated Pulp Chests, TAPPI JOURNAL May 2008
Continuous Time Domain Characterization of Mixing in Agitated Pulp Chests, TAPPI JOURNAL May 2008
Journal articles
An Assessment of Gasification-Based Biorefining at Kraft Pulp and Paper Mills in the United States, Part A: Background and Assumptions, TAPPI JOURNAL November 2008
An Assessment of Gasification-Based Biorefining at Kraft Pulp and Paper Mills in the United States, Part A: Background and Assumptions, TAPPI JOURNAL November 2008
Journal articles
Improvement of the Fiber-Bonding Capacity of Unbleached Recycled Pulp by the Laccase/Mediator Treatment, TAPPI JOURNAL October 2008
Improvement of the Fiber-Bonding Capacity of Unbleached Recycled Pulp by the Laccase/Mediator Treatment, TAPPI JOURNAL October 2008
Journal articles
Indicators for forecasting "pitch season",TAPPI JOURNAL, December 2002
Indicators for forecasting "pitch season",TAPPI JOURNAL, December 2002
Journal articles
Using peel as a measure of paper surface strength, Solutions! & TAPPI JOURNAL, July 2004, Vol. 3(7) (473KB)
Using peel as a measure of paper surface strength, Solutions! & TAPPI JOURNAL, July 2004, Vol. 3(7) (473KB)
Journal articles
Rosin sizing under neutral-alkaline papermaking conditions, TAPPI JOURNAL, Online Exclusive, July 2004, Vol. 3(7) (212KB)
Rosin sizing under neutral-alkaline papermaking conditions, TAPPI JOURNAL, Online Exclusive, July 2004, Vol. 3(7) (212KB)
Conference papers
The buildup of dissolved solids in closed white water systems, Solutions! & TAPPI JOURNAL, August 2004, Vol. 3(8) (209KB)
The buildup of dissolved solids in closed white water systems, Solutions! & TAPPI JOURNAL, August 2004, Vol. 3(8) (209KB)
Journal articles
Paper structure and printability as controlled by the fibrous elements, Solutions! & TAPPI JOURNAL, June 2004, Vol. 3(6) (528KB)
Paper structure and printability as controlled by the fibrous elements, Solutions! & TAPPI JOURNAL, June 2004, Vol. 3(6) (528KB)
Journal articles
Development of a functional filler: swelling sericite, Solutions! & TAPPI JOURNAL, June 2004, Vol. 3(6) (408KB)
Development of a functional filler: swelling sericite, Solutions! & TAPPI JOURNAL, June 2004, Vol. 3(6) (408KB)