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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
Conventional and Stratified Forming of Office Paper Grades, TAPPI JOURNAL, May 1998, Vol. 81(5)

Conventional and Stratified Forming of Office Paper Grades, TAPPI JOURNAL, May 1998, Vol. 81(5)

Journal articles
Open Access
KCL-Pakka: A Tool for Simulating Paper Properties, TAPPI JOURNAL, May 1998, Vol. 81(5)

KCL-Pakka: A Tool for Simulating Paper Properties, TAPPI JOURNAL, May 1998, Vol. 81(5)

Journal articles
Open Access
Using Confocal Microscopy to Characterize the Collapse Behavior of Fibers, TAPPI JOURNAL, May 1998, Vol. 81(5)

Using Confocal Microscopy to Characterize the Collapse Behavior of Fibers, TAPPI JOURNAL, May 1998, Vol. 81(5)

Journal articles
Open Access
Paper friction influence of measurement conditions, TAPPI JOURNAL, May 1998, Vol. 81(5)

Paper friction influence of measurement conditions, TAPPI JOURNAL, May 1998, Vol. 81(5)

Journal articles
Open Access
Comparing coating heads on a pilot coater: A call for reliable results, TAPPI JOURNAL, May 1998, Vol. 81(5)

Comparing coating heads on a pilot coater: a call for reliable results, TAPPI JOURNAL, May 1998, Vol. 81(5)

Journal articles
Open Access
Rheological investigations of caco3 slurries in the metering nip of a metering size press, TAPPI JOURNAL, May 1998, Vol. 81(5)

Rheological investigations of caco3 slurries in the metering nip of a metering size press, TAPPI JOURNAL, May 1998, Vol. 81(5)

Journal articles
Open Access
Coating structure for obtaining high print gloss, TAPPI JOURNAL, May 1998, Vol. 81(5)

Coating structure for obtaining high print gloss, TAPPI JOURNAL, May 1998, Vol. 81(5)

Journal articles
Open Access
Shop talk: metering size press drying and web-handling systems, part 1, TAPPI JOURNAL, May 1998, Vol. 81(5)

Shop talk: metering size press drying and web-handling systems, part 1, TAPPI JOURNAL, May 1998, Vol. 81(5)

Journal articles
Open Access
Color calibration standards (D65) change, TAPPI JOURNAL, May 1998, Vol. 81(5)

Color calibration standards (d65) change, TAPPI JOURNAL, May 1998, Vol. 81(5)

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