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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
Magazine articles
Open Access
Combustion behavior of kraft black liquor droplets from hot

Combustion behavior of kraft black liquor droplets from hot water pretreated hardwood and softwood chips, November 2016 TAPPI JOURNAL

Journal articles
Magazine articles
Open Access
Novel CaCO3-polymer nanocomposite fillers for the improvemen

Novel CaCO3-polymer nanocomposite fillers for the improvement of bagasse-based papers, November 2016 TAPPI JOURNAL

Journal articles
Open Access
Preparation and characterization of bioactive and breathable

Preparation and characterization of bioactive and breathable polyvinyl alcohol nanowebs using a combinational approach, October 2016 TAPPI JOURNAL

Journal articles
Open Access
Predictive modeling of high pressure naem-catalyzed (hp-alpulp) organosolv pulping of spruce, TAPPI JOURNAL, April 2001, Vol. 84(4)

Predictive modeling of high pressure naem-catalyzed (hp-alpulp) organosolv pulping of spruce, TAPPI JOURNAL, April 2001, Vol. 84(4)

Journal articles
Open Access
Natural variability and the second crop, TAPPI JOURNAL, April 2001, Vol. 84(4)

Natural variability and the second crop, TAPPI JOURNAL, April 2001, Vol. 84(4)

Journal articles
Open Access
Studies of the dynamic compressibility of water-saturated fiber networks, TAPPI JOURNAL, April 2001, Vol. 84(4)

Studies of the dynamic compressibility of water-saturated fiber networks, TAPPI JOURNAL, April 2001, Vol. 84(4)

Journal articles
Open Access
Laboratory study of shoe pressing for low basis weight paper applications, TAPPI JOURNAL, April 2001, Vol. 84(4)

Laboratory study of shoe pressing for low basis weight paper applications, TAPPI JOURNAL, April 2001, Vol. 84(4)

Journal articles
Open Access
What can be patented?, TAPPI JOURNAL, August 2001, Vol. 84(8)

What can be patented?, TAPPI JOURNAL, August 2001, Vol. 84(8)

Journal articles
Open Access
Gmundâ??s special place in the heart of Europe, TAPPI JOURNAL, August 2001, Vol. 84(8)

Gmund’s special place in the heart of Europe, TAPPI JOURNAL, August 2001, Vol. 84(8)

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