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How Emerging IIoT Technologies can Impact the Paper Production of the Future13th Annual RISI Latin American Conference| São Paulo| August 15, 2018

Agenda

How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public

1. Changing world

2. What means Papermaking 4.0 for Voith?

3. Technologies and Challenges through the Digitalization road

4. Use cases

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Changing world

How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 3


The world’s most valuable resource today is data


Information & Communication technologies for consumer markets enter the industrial space

Mobile World Congress 2016


The Digital Footprint of People and Things grows rapidly


Cloud Computing – Shift from Central to Distribute Computing


Open Source and Communitiesget important for the Industry


Mobile Computing and Connectivitychange our Way of Interacting


The Generation of Digital Nativesenters the Workforce


Automation and InformationTechnology will grow together

Is the paper industry 4.0 ready?


4.0 ready

Major invest required?

No! Basis is set!

Paper industry is well prepared to enter the 1st phase of

Industrie 4.0New Automation Systems

New Sensor technology

Smart Aggregates

Long term data storage?

Interfaces are available

Automation level is high

Gradual increase possible

No data – No Big Data

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What means Papermaking 4.0 for Voith?


Our Goal – Digital TwinUtilize structured and cross-linked information in the cloud

Benefits• Simulate

e.g. rebuilds• Predict

e.g. mechanical failures• Optimize

e.g. production process• Test

e.g. process changes• Recognize

e.g. saving potentials• Plan

e.g. logistics


Apps

Asset information

Real-time information

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Papermaking 4.0 – Targets


Up to10% higherProductivity

Break & Change time

50% less

Off-SpecProduction

50% less

UnplannedDowntime

50% less

Energy

10% less

Materials

10% less

Labor

20% less

Fiber

7% less

Up to10% lower

operating costs

$8.5 M Savings*

$88.7 M/yr* Op. Cost

€Maintenance

Cost

20% less

*example 300,000t/yr. B & P

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Papermaking 4.0 Solution PortfolioThe sum of three big talents

OnEfficiency: The modular solution visualise, stabilise & optimise.

OnCare: Intelligent condition based, predictive maintenance.

SmartService: The service you need before you know it.

Pm4.0

• CMS• CMMS• Diagnostics

• Sensors• Controls• Actuators

• Analytics• Remote• Upgrades


Technologies and Challenges through the Digitalization road


Key Technologies for IIoT at Papermaking 4.0


Machines connected using open protocols and interchanging

data through cybersafely and high speed networks.

IIoT

Machine Learning dealing with Terabytes of

information to enablePredictive Analytics.

Big Data

AI

Simulate real conditions withreal data previous to

implementation and enhancehuman interaction with

machines.

Mixed RealitySimulation

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Assets:DynamicData

Assets: Static Data

Process/ Operations

How to make use of data?Connect Systems, Data & Expert Know-How!


Commercial/Market/ HR

Collect & Store Visualize Analyze Optimize AutopilotMeasure/ Generate

Control/Schedule

Operations

Sensors

Maintenance & Technical Master Data

Automatic optimization of operation and maintenance

Structure

Clean

Connect

Rule based analysis

Machine learning

Cluster analysis

Benchmarking

Expert analysis

Rule based process control

Advanced process control

Workflows

Scheduling of maintenance tasks

Alarms

Trends

Documents

Correlations

Recommend actions to optimize operations & Maintenance based on expert know-how, analysis or simulation results

Business Data

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From classical to the futureStepwise Approach

5. Machine Digital Twin

Forming Section

OnCareAsset Mgmt

DataAnalytics

OnCumulus Asset database

Real Time ConditionMonitoring

Preventative Maintenance Routines

Laboratory Data

Field sensors

Operative data

Press Rolls

Uhle Boxes

HydraulicsFelts

Press Section

4. Section Digital Twin

Forming Section

Headbox

Vacuum elements

Rolls

3. Module Digital Twin2. Smart

component1. Component


Update or Technological Upgrade?• Investment, Technology Life Cycle, Operational Risk

and Potential Benefits with new technologies.

OnEfficiency.Strength to reduced raw material consumption

Roll health monitoring

Condition based monitoring to reduced downtime

Value-driven Intelligence

Industrial Cyber Security Data Privacy and Protection


Hardware• Hardening• Segmentation• Encryption• Availability Check

Process• Compliance• Data Safety• Backup Concept• Quality Assurance• Vulnerability-

Management• Risk-Management

Certificates• Coding Guidelines• Standardization

(IEC27001, IEC62443 etc.)

Software• Hardening• Patch Management• Pen testing• SDLC• Authentication

Interfaces• Network Security• Firewall Concept• Performance Check

Data transfer• Encryption

Network, Security & Privacy

Edge / Fog Development Cloud Infrastructure Cloud Development Front-end Framework

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13th RISI Latin America Conference | São Paulo | August, 13 - 15, 2018

Skill

#

ContractorsOperators & Maintenance Technicians Subject Matter

ExpertsToday’s situation• Ageing workforce: 90% of

the knowledge is stored in the head of people.

• Free-floating skills driven operation – who’s in the driver seat?

• Knowledge transfer is reduced to a minimum.

• Protectionism – it’s a human aspect.

Situation in 2027, ten years from now:

• The great brain-drain, the +65 will retire and take all knowledge with them.

• This effect will have an serious impact of the productivity and competiveness of the industry in the western hemisphere.

• Is this the day after tomorrow? we might think so but it is actually not if we make the right decisions and take the right measures.

Scenario factory of the future:

• The reliability of an operation for is 80% be determined by systems and 20% by humans

• All for operation and maintenance useful information must be easy to access

• There will be a shift to remote operation of production facilities

• Contractors and technicians will play an important role.

Skill distribution chart

And how about the people?Paper Mill of the Future

TodayTomorrow

Human factors shift

Human Factor Non-Human Factor

Today 80% of the company performance is determined by people.

Knowhow, Teamwork and Communication skills of people have an significant impact of the success of an enterprise.

Tomorrow 80% of the performance will be controlled and managed by systems.

The remaining 20% will still be in the hands of humans; however this part must be structured by means of processes and procedures.


Voith’s approach to digitizationDRIVE – Preparing all employees for the digital future


• DRIVE Program empowers all employees to develop their digital talent in every level of Voith organization.

• It invites Voithians to an inspiring learning journey that develops both their digital capabilities and soft skills to match the needs of Industry 4.0 era.

• Building our digital talent enables us to become the digital partner to our customers.

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“One factor more than any other will determine which companies turn digital to their advantage. That critical element is people: the talented employees who are able to use existing digital technologies and adapt to evolving methods and new approaches.”- Boston Consulting Company

Use cases


OnCall VideoRemote Service Video Collaboration


In case of equipment or process problems, OnCall Video ensures fast availability and

performance restoration by virtual onsite presence of service experts.

OnCall Video

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Benefits gained from OnCall Video


Improved access toexperts

Reduced travel time & expenses

Multiple global expertsaccess possible

Off-line review ofsession possible(e.g. for training)

Improved response& reduced time to

resolution

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OnEfficiency StrengthSuccess story: Double ply board 450,000 tons per yr.


Savings

Main features• VirtualSensors to predict strength properties in

real time• Automatic control of strength• Cost based controller adjustment• Various combinations possible• Stable product quality at minimum cost

Total 1.32M €/yr.

Continuousimprovements

Stableprocess

Processoptimization

Optimum quality

Lower cost of ownership

Key benefits

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Virtual SensorReal time measurement without “physical sensor”

Process Data

Machine Data

Quality and Lab. Data

Physical Model

∑

Statistical Model

Virtual Sensor

Operation

Advanced Control

Visualization

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Virtual Sensors – Eliminating delay timesKnowing what the lab is going to measure in 1.5 h


Burst

No of samples 3336

Time period 2016-05 to 2016-11

R² correlation P1 0.94

No of parameters 20

Correlation of the model

Typical accuracy: 98 out of 100 predictions are within ±5 % of the measuring value

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A high number of paper properties can be predicted with virtual sensors


Quality general Paper strength Printability

Basis weight SCT Porosity

Ash content CMT Mottling

Moisture Burst Color

Thickness Tensile MD/CD Roughness

Density STFI

Curl (MD/CD) Mullen

Stiffness

Ply Bond

Ring Crush

Fold crack resistance

Currently build models

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OnCumulus.PlatformYour Centralized, Reliable Data Hub


• The IIoT platform OnCumulus.Platform as a hub for data for all types of sources

• One centralized, reliable access point for their data

• Fast, reliable and secure access to data from local machines and systems in the cloud

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OnCumulus.SuiteUnique user experience and user interface design


Made by engineersfor engineers

Made by interaction designers based on user needs

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OnCumulus.SuiteApplications Overview


Customers can access their data in near real-time and take the first step towards optimizing their operating processes with personalized, role-based dashboards.

Analyzer Coordinator Cockpit

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AnalyzerUncover the Potential Hidden in Your Data


MoreTransparency

Key Benefits

ProductivityIncrease

Safe Decision-making

Time Savings

$

LessComplexity

Main Features• Visualize data from all available data sources of

your plant• Structured data storage due to Voith’s domain

knowledge• Various possibilities to display data for analysis• Intuitive tool for troubleshooting

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Main Features• Supports less bureaucracy philosophy• Structured guidance for all operational

processes • Best possible task description and possibility to

create best practices • Automatic documentation and reporting

functions• Trigger checklists automatically e.g. for events

CoordinatorCapture and Store Your Knowledge


MoreTransparency

Key Benefits

Time Savings

$

Knowledge Capture

ReducingFailure

ReducedBureaucracy

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CockpitMaintain Optimal Operations and Discover Optimization


Main Features• Combined information on past, present and

future values of a parameter• Automated technological limits • Complete process hierarchy can be displayed• Possibility for pre-configuration based on Voith’s

domain knowledge

MoreTransparency

Key Benefits

Time Savings

$

Knowledge Capture

StableProcess

Root CauseIdentifikation

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Thank you!ContactLeandro OliveiraSVP Sales and Marketing, Voith Digital Solutions South America [email protected]

Follow us on Social Media

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Voith Group

http://www.linkedin.com/company/voith-paper/

@Voith_Paper

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