Each performance indicator includes a series of indexes derived from specific machine tests. Each test is performed inside product specifications, utilizing ABB’s diagnostic tools and methodologies. The resulting index is used to evaluate the performance level of different areas of the tissue process including:
− Mechanical vibration and rotational frequencies
− Machine and cross direction controls
− Lab testing procedures
− Sheet break recovery
− Process control system performance
− Coordinated speed control
− Grade change control
Identifying machine area under-performance 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 tissue machine control.
In order to provide practical solutions for problems often identified in the tissue making process, ABB has developed defined, logical optimization steps for each machine area. The numerical result or index of each test points to the machine area problem and also points to the bottleneck location in the optimization sequence.
Once the entry point has been established for each machine area, the solution to the performance bottleneck and the remaining steps to optimize the process become clear.
The Machine Response indicator is used to determine a performance index for the machine-direction controls. The test entry point is defined by the specific machine tests and data analysis associated with this performance indicator.
The Machine Response indicator includes multi-level testing and analysis applied to Dry Stock, Tissue Weight, Moisture (hood temperature and Yankee steam), and Rush/Drag. Similar testing methodologies are involved with each performance indicator.
Complete Machine Area testing sequences require three to five working days to collect the data required for the diagnosis and to compare improvement recommendations.
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 machine diagnosis.
− Executive Report provides benchmark results, summary of findings, financial impact of recommendations, and an actionable improvement plan, based on the machine diagnosis.