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QCS Transition Performance Fingerprint

Analysis of transition time, control and moisture response, and setpoint prediction, provides a transition
performance benchmark. The resulting diagnostic report provides improvement recommendations and associated return on investment (ROI).

Typical savings potential: $60,000 – $120,000

The Transition MD Grade Change Fingerprint is a process performance diagnostic service for paper-making transition or grade change optimization. It is a platform-independent, noninvasive service that can be applied to machines with frequent grade changes. Most machines that average one to two grade changes a day can benefit from this Fingerprint.

The diagnostic Fingerprint includes an engineered troubleshooting methodology to identify barriers to optimized performance and improved profitability. It generates both a performance benchmark and an improvement plan, consisting of a set of improvement opportunities which are prioritized based on estimated economic benefits.

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Overview
Performance Indicators
Improvement Plan
Delivery Schedule

Benefits
− Facilitates management decisions by focusing on high-impact opportunities for improvement
− Provides clear path to quickly close performance gaps by using the proposed improvement plan
− Provides a solid foundation for continuous improvement based on transition data

Features
− Access to ABB optimization experts
− Transition Process Performance Benchmarking
− Detailed ROI-based improvement plan
− Clear communications during data collection and diagnosis activities

Transition Performance Indicators

The Fingerprint involves comprehensive testing and analysis designed to measure five key Performance Indicators.
These Performance Indicators are used to assess transition performance and improvement area potential.
− Transition Time
− Moisture Response
− Historical Analysis
− Control Response
− Setpoint Prediction

Transition Process Analysis
Each performance indicator is made up of a series of indices derived from 25 to 35 collected historical transition data. The resulting index is used to evaluate the performance level of different areas of the paper transition process including but not limited to:
− Level 1 control response
   − Stock flow, fillers, steam, total head, and speed
− Level 2 control response
   − Weight, moisture, ash, and headbox
− Grade change configuration
− Limiting product specification limits
− Control constraint handling and setup

Identifying that a transition process area is under-performing is the first step in the improvement process. Understanding the problem and having the expertise to provide solutions is assured through ABB’s extensive experience in paper machine transition control.

In order to provide practical solutions for problems often identified in the transition process, ABB has developed defined, logical optimization steps for each transition process area.

Once ABB performs the Fingerprint, the steps to optimize the process and remove the performance bottleneck are identified. The improvement plan is developed using this information.

Benchmarking
The initial performance benchmark is defined by the specific machine tests and data analysis associated with the Performance Indicators.

The Transition Response indicator includes multilevel testing and analysis applied to Transition, Level 1 Controls, and Level 2 Controls Performance Indicator. Complete Transition Process Area testing sequences require 25 to 35 collected transition data to complete the diagnosis and develop improvement recommendations.

Reporting
An Executive Report and a Technical Report are provided to disclose the findings and  recommendations of the process performance diagnosis.
Technical Report provides supporting data collected during the transition process diagnosis.
− Executive Report provides benchmark results, summary of findings, financial impact of recommendations, and an actionable improvement plan, based on the transition process diagnosis.

Improvement Plan

The improvement plan defines how to resolve the performance bottleneck and how to move towards optimal performance. In addition, the associated financial impact for each recommendation is provided.

Based upon the findings, recommendations may include but are not limited to level 1 PID control, level 2 MD control, optimizing or adding control logic, updating operator procedures for grade change, or re-tuning transition setup.

The Transition MD Grade Change Fingerprint is the first step in achieving and sustaining higher performance levels. Annual Fingerprint, Implementation, and Sustaining services are recommended as part of your service agreement to achieve and continue the improvement process. These can be scheduled within a single- or multi-year service agreement.

Shade Transition Fingerprint
Based on the analysis of observed shade changes during the Transition Fingerprint, a Shade Transition Fingerprint may be recommended. This Fingerprint requires detailed analysis and quantification of up to one month of shade changes.

Delivery Schedule

Preliminary

Project introduction meeting
Set up and verify data collection software
Collect 25 to 35 transitions

Analysis

Discuss transition operation with operators
Perform detailed data analysis
Identify transition time, control response, moisture response, and setpoint prediction indices
Complete ROI analysis based on recommendations

Reporting

Create Executive and Technical reports
Review reports with customer

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