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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
2
Changing world
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 3
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 4
The world’s most valuable resource today is data
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 5
Information & Communication technologies for consumer markets enter the industrial space
Mobile World Congress 2016
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 6
The Digital Footprint of People and Things grows rapidly
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 7
Cloud Computing – Shift from Central to Distribute Computing
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 8
Open Source and Communitiesget important for the Industry
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 9
Mobile Computing and Connectivitychange our Way of Interacting
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 10
The Generation of Digital Nativesenters the Workforce
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 11
Automation and InformationTechnology will grow together
Is the paper industry 4.0 ready?
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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?
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 13
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
Apps
Asset information
Real-time information
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Papermaking 4.0 – Targets
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
Technologies and Challenges through the Digitalization road
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 17
Key Technologies for IIoT at Papermaking 4.0
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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!
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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.
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Voith’s approach to digitizationDRIVE – Preparing all employees for the digital future
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
• 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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How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 25
“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
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OnCall VideoRemote Service Video Collaboration
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public 27
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
29
OnEfficiency StrengthSuccess story: Double ply board 450,000 tons per yr.
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
30
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
33
OnCumulus.PlatformYour Centralized, Reliable Data Hub
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
• 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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
Made by engineersfor engineers
Made by interaction designers based on user needs
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OnCumulus.SuiteApplications Overview
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
MoreTransparency
Key Benefits
Time Savings
$
Knowledge Capture
ReducingFailure
ReducedBureaucracy
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CockpitMaintain Optimal Operations and Discover Optimization
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
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
39
How Emerging IIoT Technologies can Impact the Paper Production of the Future| RISI LatAm 2018| São Paulo| Public
Thank you!ContactLeandro OliveiraSVP Sales and Marketing, Voith Digital Solutions South America [email protected]
Follow us on Social Media
40
Voith Group
http://www.linkedin.com/company/voith-paper/
@Voith_Paper
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