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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 …
IPPTA ZONAL SEMINAR 2018
❖ 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
IPPTA ZONAL SEMINAR 2018
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 …
IPPTA ZONAL SEMINAR 2018
❖ Mill Introduction
❖ Business Process Automation
❖ Implementation Benefits
❖ 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
IPPTA ZONAL SEMINAR 2018 9
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
IPPTA ZONAL SEMINAR 2018 11
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.
IPPTA ZONAL SEMINAR 2018 12
◼ 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
IPPTA ZONAL SEMINAR 2018 14
◼ Productivity Increase◼ Automatic scanning & selection of route
◼ Less manual intervention
◼ Interfacing with mill ERP
◼ An unique bar-coding system
◼ Automatic scanning and selection of route
Automation at Intermediate roll storage (IRS)
IPPTA ZONAL SEMINAR 2018 15
◼ 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
IPPTA ZONAL SEMINAR 2018 16
◼ Productivity Increase
◼ 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
◼ Interfacing with mill ERP
◼ 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
IPPTA ZONAL SEMINAR 2018 18
◼ Productivity Increase
◼ 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)
◼ Interfacing with mill ERP
◼ 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
IPPTA ZONAL SEMINAR 2018 19
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.
IPPTA ZONAL SEMINAR 2018 20
◼ Productivity Increase
◼ 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
◼ Interfacing with mill ERP
◼ 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
IPPTA ZONAL SEMINAR 2018 21
◼ Productivity Increase
◼ 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
◼ Delivered Quality & Customer Benefits
◼ 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.
IPPTA ZONAL SEMINAR 2018 22
◼ Productivity Increase
◼ 8640 bundles /day
◼ Infeed scissors lift facilitates easy feeding of reams
◼ Automatic stacker and delivery conveyor
◼ Optimization of conveyor length and bundle tracking
◼ Interfacing with mill ERP
◼ 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
IPPTA ZONAL SEMINAR 2018 23
◼ Productivity Increase
◼ 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.
◼ Delivered Quality & Customer Benefits
◼ Sea worthy packing
◼ Moisture proof packing with edgeprotection
◼ Top board and two way strapping forvertical stacking
◼ Interfacing with mill ERP
◼ 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
IPPTA ZONAL SEMINAR 2018 24
◼ Productivity Increase
◼ 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.
◼ Delivered Quality & Customer Benefits
◼ 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
◼ Interfacing with mill ERP
◼ 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 …
IPPTA ZONAL SEMINAR 2018
❖ Mill Introduction
❖ Business Process Automation
❖ Implementation Benefits
❖ Key take aways
Automation.. Transformation…Information
Customer Benefits
IPPTA ZONAL SEMINAR 2018
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
IPPTA ZONAL SEMINAR 2018 27
Outline …
IPPTA ZONAL SEMINAR 2018
❖ Mill Introduction
❖ Business Process Automation
❖ Implementation Benefits
❖ Key take aways
Automation.. Transformation…Information
Lessons learnt
IPPTA ZONAL SEMINAR 2018
◼ 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.
IPPTA ZONAL SEMINAR 2018 31
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)
◼ 32 Years Experience
◼ Design, Erection, Projects commissioning
and maintenance in Petrochemical and chemical industries.
◼ Skilled in Process
Control, Paper machine & Pulp Process Engineering
DGM ( Projects)
◼ 30 Years Experience
◼ 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
IPPTA ZONAL SEMINAR 2018