business process automation. zonal -2-2018.10 tnpl ppt.pdf · 2019-04-17 · business process...

Business Process Automation for

Process, Productivity, Quality & Marketing Optimization

at

TNPL Board Machine Finishing House

IPPTA ZONAL SEMINAR 2018

Authored by S.Senthil P. Prince Tholkappian AM (Inst),TNPL AGM ( Board Plant Operations),TNPL

V.Thirupathy S.Nandagopal

DGM ( Inst), TNPL DGM ( Projects),TNPL

1

Outline …


❖ Mill Introduction

❖ Business Process Automation

❖ Implementation Benefits

❖ Key take aways

Automation.. Transformation…Information

Integrated Pulp & Paper Mill at TNPL – Unit-1, Karur, district Tamilnadu state.

❖ 1985 : PM # 1 for 50,000 tpa of Newsprint & 40,000 tpa of Fine Paper

❖ 1995 : PM # 2 for doubling the capacity from 90,000 to 180,000 tpa

❖ 2003-08 : Pulp Mill Development Program increased capcities by 65,000 tpa

❖ 2010 : PM # 3 for 1,55,000 tpa of Copier & P&W paper


TNPL in Brief …

4

PM#1 PM#2 PM#3

BM#4

Multi layered double coated

Board Mill at TNPL – Unit- 2,

Trichy district, Tamilnadu state

in 2015 for 200,000 tpa

TNPL Growth in Production capacity ...

1 2 3 4 5 61985 1996 2003 2008 2010 2015

90000

180000

230000

245000

400000

600000

PM

’s R

ebuild

PM

#2

PM

’s R

ebuild

+

EC

F P

ulp

PM

#1

+ P

M#2

+ P

M#3

PM

#1

Paper made

from ECF Pulp

3 P

Ms +

BM

4(G

reen

field

)

Outline …





❖ Key take aways

Automation.. Transformation…Information……

Why Automation?

IPPTA ZONAL SEMINAR 2018 7

❖ Buyers Market

❖ Skilled work force

❖ Generation next

❖ Attrition rate

❖ Stake holders inclusive growth

❖ Business value

❖ Technology to meet Future challenges

Modern Winder

& RHS &packing

Conversion

&

Finishing

Sheeters

Palletisers

ASRS

and

despatch

Marketing

Orders

PLC and

Aautomation

ERP -MIS

Modern Finishing House

with Business Process Automation

Finishing processes are closer to the end userTraditional Finishing House

Manual and un coordinated

• Stand alone equipments

• Independent workflow

• Manual and interrupted flow

• Inconsistent Quality

• Repetitive tasks and accidents

• Slow Processes

• Seamless Integration - PLC

• Integrated Solution with ERP

• Customized BPA

• Consistent quality

• Productivity , Reliability with safety

• Fast Process

Integrated

solutions

Why Automation at Finishing House?

❖ Conversion challenges

❖ Designing a customized solution

❖ Leveraging on domain expertise

❖ Automation with ERP Interface

❖ Reliability


Integrated Automated

solution creates value

Self Evidence – Vision to Reality

❖ Customer Satisfaction

❖ Right product, right quality at right time.

❖ On time delivery (OTD)

❖ Customer orders tracked from Sale

Order receipt portal to Despatch.

❖ Business value

Business Process Automation at TNPL

10IPPTA ZONAL SEMINAR 2018

Sale order link at Winder


Automation at Winder

◼ Delivered Quality and Customer Benefits

◼ Automatic slitter positioning using

Temposonic sensor to ensure

Exact Size

◼ Tension control, speed curve, drum

load sharing to get Tight

Winding.

◼ Shrinkage factoring and automatic

core positioning prevents Core

projection.

◼ Clean cut quality and No dust

/fluff

◼ Safety and trouble shooting◼ Light barrier and Safety curtain

◼ Logic sequence display ensures easytrouble shooting

◼ Manual operations permitted only ifthe basic interlocks are satisfied.


◼ Productivity Increase

◼ Automatic Slitter Positioning

◼ Automatic set change

◼ Automatic gluing

◼ Automatic core feeding

◼ Interfacing with mill ERP

◼ Traceability of the product fromproduction to despatch using aunique bar-coding system

WINDERTT

Stre

tch

W

rap

pin

g

TT

TT

TT

Intermediate Reel Storage (IRS)

TT

TT

Kicker

Sheeters

Kicker

Kraft Wrapping

TT

R1 (Route1) Reels to Sheeter or rewinder through IRSR2 (Route2) - R2 Reels To Kraft Wrapping through IRSR3 (Route 3) - Reels to Sheeter or Rewinder DirectR4 (Route 4) - Reels to Kraft Wrapping DirectR5 (Route 5) - Bypass (Manual)

R5

R5

R4

R4

R4

R4

R4

R4

R3

R3

R3R3

R3

R3

R2

R2

R2

R2R2

R1

R1

R1

R1

R1 R1

Rewinder

Transfer Car

Automatic Reel handling system

Kicker Kicker

TT - Turn Table

Reel 1

Scanning ReelsSending Barcode to ERPGetting QC and Destination

Scanning ReelsDecide IRS or Direct

Reel4

Reel2

Reel 3

Reel5

Automation at Reel handling system

◼ Delivered Quality and Customer Benefits

◼ Width and Diameter validation with ERP

avoids reels mixup

◼ Online weighing system

◼ No forklift handling - Slat conveyor

transportations - No reel Damage

◼ Less manual intervention so better

product hygiene

◼ Choice of either Kraft or Film wrapping

◼ Safety and trouble shooting◼ Two sensor methods for all critical applications

◼ Safety curtains or safety barriers


◼ Productivity Increase◼ Automatic scanning & selection of route

◼ Less manual intervention


◼ An unique bar-coding system

◼ Automatic scanning and selection of route

Automation at Intermediate roll storage (IRS)


◼ Replacing human tasks.◼ Smallest foot print

◼ Machine production reels are taken 24/7 on any random order◼ Delivery on FIFO basis / on demand reels◼ IRS has 1272 bins for storing 13000 SKU of 30000 T

◼ Floating methodology is used for stacker crane movement.◼ Robotic stacker cranes pick and place reels using encoder controlled transfer cars.◼ The stacker cranes are positioned using laser distance and additional encoders.

◼ IRS is controlled by PLC based Warehouse Management System (WMS) through intranet.

Automated Intermediate Roll storage (IRS)

◼ Safety and trouble shooting◼ Completely automated

◼ No zone for humans inside storage area

◼ Wherever critical two sensor are used

◼ Safety curtains or safety barriers



◼ 13000 SKU with 2 robotic cranes

◼ Storage and retrieval based on SKU, Variety, Age, sale order

◼ No handling loss, no stretch film

◼ Less manual intervention

◼ 15 reels/ hour for sheeter

◼ 45 reels /hour delivery for wrapping

◼ Reel on demand


◼ Delivery request directly from ERP

◼ Automatic report generation(Stock on hand, variety wise, Age wise, Fast moving, slow moving)

◼ Delivered Quality & Customer Benefits◼ Sheet flatness, shade stability and Reel stability till the core end due to high level of

protection from light◼ No forklift handling – Crane and Slat conveyor transportations - No reel Damage◼ On time delivery(OTD)◼ Better customer service due to the possibility of holding inventory

◼ Width and Diameter validation

DB in PLCBuffer

ConveyorWrapping

masterPress Plate Turn table

Weighing Conveyor

Delivery Conveyor

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Automatic Spiral kraft wrapping machine

Reel ID Data Will be moved Based upon Entry and Exit

Sensor of Each conveyor

TT

Buffer Conveyor

Wrapping Master Press Plate

Turn

Table

Weighing Conveyor

Delivery Conveyor

Safety Barrier

Safety Barrier

Reel 0

1Reel 0

2Reel 0

3Reel 0

4Reel 0

5Reel 0

6

Reel

ID 01

Reel

ID 02

Reel

ID 03

Reel

ID 04

Reel

ID 05

Reel

ID 06

Scanner

Automatic spiral kraft wrapping machine

◼ Delivered Quality & Customer Benefits

◼ Moisture proof tight wrapping &

quality packing.

◼ Edge protection with additional layers

in the edges.

◼ Hot melt gluing - gives better packing.

Accurate weight

◼ No human intervention so better

product hygiene

◼ Safety and trouble shooting◼ Completely automated and no

manpower required inside fencedarea

◼ Specific alarms can be generated foreasy trouble shooting.

◼ Safety curtains or safety barriers toensure Machine Safety



◼ Completely automated except side disc placement

◼ Overlap and number of layers are automatically selected from ERP.

◼ Capable of packing 45 reels in an hour

◼ Optimum wrapper consumption by auto selection of wrapper mode.

( Double band / Triple band/ Spiral wrap)


◼ Width and Diameter validation

◼ QC approval Interlock

◼ Automatic Label with Actual weight by ERP to avoid mistakes.

◼ Each reel movement is stored in PLC.

◼ After kraft wrapping , PLC measures the reel weight and sends to ERP with barcode.

Automated High speed sheeter


Web inspection system

Captured defects

Automated High speed sheeter

◼ Safety and trouble shooting◼ Safety light barriers in laybouy

section can be acknowledged locallyonly from the field ensuringenhanced safety for men andmachine.



◼ Automatic format change, Slitter positioning, overlapping, separating shoes positioning, side joggers positioning, end stopper plate positioning.

◼ Automatic pallet change withoutstopping the sheeter

◼ Automatic decurler and Auto unwind stand braking system improves runnability


◼ QC approval Interlock

◼ Destination code for further Ream packing or Bulk palletizing .

◼ Delivered Quality & CustomerBenefits

◼ Cutting accuracy of 0.1 mm

◼ No cross cutting, Clean cut edges

and No rough cutting.

◼ PU coated stopper plates eliminates

sheet edge damages.

◼ Automatic decurler and static

eliminators keeps the sheets flat

and provides better piling.

◼ Online WIS detect defects and Reel

joints, rejects sheets without

stopping the sheeter with

comprehensive.

◼ Ream counting and Sheet counting

with accuracy +/- 1 cut is achieved

with Tab inserters.

◼ No dust

Automatic Ream wrapping machine



◼ Hydraulic servo controlled system Infeed Scissorlifts reduces operator fatigue

◼ Intelligent Robotic System with pneumatic and highprecision positioning system is used in infeedconveyor to pick and place reams

◼ Automated wrapper size selection, wrapper lengthselection, folding, gluing, side tucking,

◼ 12500 reams /day

◼ Hot melt gluing system with faster bonding

◼ Unique flying carpet double stacking laybouy

◼ Interfacing PLC with mill ERP

◼ Infeed – scanning – ERP validation- label printingcommand to PLC – auto labeller – auto pasting onine.

Customer BenefitsGood quality tight and neat stacking and packingNeatly stacked reams with easy identification throughproperly placed labels

Safety and trouble shootingSafety light barriers * Diagnostic tools *Specific alarms

Automation in Shrink bundling machine


◼ Automatic temperature control of the

Oven ensures the quality

◼ Moisture proof packing

◼ Bundle weight restriction for easy

handling(55 KGS)

◼ Safety and trouble shooting◼ Manual operations are also

permitted after satisfying the basicinterlocks

◼ Diagnostic tools built in the PLCmakes trouble shooting easy asspecific alarms can be generated.



◼ 8640 bundles /day

◼ Infeed scissors lift facilitates easy feeding of reams

◼ Automatic stacker and delivery conveyor

◼ Optimization of conveyor length and bundle tracking


◼ Scanning of pallets is done in the entry and validated in ERP.

◼ ERP provides information about number of reams per bundle.

.

Automation in Pallet wrapping machine



◼ Turn tables help Top lid placement, edge protector placement

◼ Both directions strapping enables 750 pallets/day

◼ Safety and trouble shooting◼ Manual operations are also permitted

after satisfying the basic interlocks.


◼ Sea worthy packing

◼ Moisture proof packing with edgeprotection

◼ Top board and two way strapping forvertical stacking


◼ For auto labelling, PLC and ERP are interfaced

◼ Actual weight captured & to ERP and Auto A4 label will be printed and Pasted

Finished Goods Storage and Despatch



◼ Space saving for handling 13000 SKU with a capacity to store 8000 T

◼ Storage and retrieval based on SKU based on Variety, Age, sale order.

◼ On demand automated storage and retrieval of the right goods in shortest time.


◼ Moisture proof Storage

◼ No fork lift movement helps in retaining the quality of the bundles.

◼ Intelligent WMS avoids wrong delivery & improved accuracy of storage

◼ On time delivery with Fast and accurate automated retrieval resulting in faster service


◼ Automatic Finished Goods report generation

◼ Delivery request directly from ERP based upon priority

◼ Safety and trouble shooting

◼ Safety curtains or safety barriers to ensure Machine Safety

◼ Manual operations are also permitted after satisfying the basic interlocks.

Outline …





❖ Key take aways


Customer Benefits


ERP interface for faster delivery, product traceability

Less physical handling , more product Hygiene and Better quality

Sheeters & Packing machines – increased production and less human error

High level of dimensional accuracy at Sheeters ( no Size variation & no Cross cut)

Automated Converting lines are flexible Kraft packing - film packing for reels / sheets

IRS protects from light & heat, improves Sheet Flatness, Reels stability till the core end

Less complaints

Less Finishing loss

Reduction of FG inventory

Energy efficient equipments

Increased safety for men & machinery

Historical data for analysis & improvement

Optimum use of raw material and consumables

Better planning & service , better customer satisfaction

Easy ,correct & timely decision making due to availability of customized reports

26

Continual improvement

TNPL continues to improve its finishing house operations, with further

automation and computerization of the Work in Process.

The work is already begun for moving from the "existing customized

data interface through PLC" to “Integrated Automation with

Industrial Internet of Things (IIoT)".

◼ Some of such future plans are:

◼ Automatic despatch planning (ADP)

◼ Sheeting plan based on TPA (Truck placement advice)

◼ Customized Deckle optimization program

◼ Automatic Sheeter size change through ERP


Outline …





❖ Key take aways


Lessons learnt


◼ Large initial investment

Automated ,High speed Winders, Rewinders & Reel wrapping machines follow the higher production rates of the Board Machine. Quick ROI for the management

◼ Concept to commissioning Previous product data knowledge, focused objectives are necessary for the basic and detailengineering to correctly select and size the equipments

◼ Higher volume production

At lesser foot print. Increased profitability, to remain competitive and to get the ROI. Satellite centers can be avoided and mill despatch is possible.

◼ Extent of Automation Choose automation depending on the objectives at Reel handling systems, Sheeters, automated ware houses ,ream packing, pallet packing etc.

◼ Extensive training Training the maintenance personnel for operating the automated machines are needed for quick trouble shooting and problem solving.

29

Key takeaways from the FH Automation

◼ Ontime Delivery (OTD) improved beyond 80%

◼ Average service time (Mill to despatch) - 20 – 25 days FOR delivery

◼ Satellite conversion centre is not mandatory

❑ Equipment automation is SUSTAINABLE & RELIABLE

❑ STRATEGIC tool for future challenges.

❑ Automation with ERP interface adds business value .

❑ In house domain expertise is the key.

❑ Effective Design through implementation and efficient execution by Mill team.

No one is the best – scope for continual improvement IPPTA ZONAL SEMINAR 2018 30

About the authors

AM ( Instrumentation)

◼ 15 Years experience

◼ Handled various DCS and Field instruments

related to Petrochemical, Pharma, Power, Pulp and Paper.

◼ Active involvement in

Engineering, Erection and Commissioning of BM4 & Finishing House.


AGM ( Plant Operations)

◼ 29 Years Experience

◼ Wide experience in maintenance and Project Engineering, Erection & Commissioning of Paper & Board Machines.

◼ Skilled in Process trouble shooting and problem solving in Paper /Board Machines

DGM( Instrumentation)


◼ Design, Erection, Projects commissioning

and maintenance in Petrochemical and chemical industries.

◼ Skilled in Process

Control, Paper machine & Pulp Process Engineering

DGM ( Projects)


◼ Wide experience in Maintenance and

Project management of Paper and Paper Board machines.

◼ Concept to

Commissioning and optimization experience in Paper &

Board & Cement .

Thank you IPPTA


business process automation. zonal -2-2018.10 tnpl ppt.pdf · 2019-04-17 · business process...

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