The Evolution of PI System #16 at Appleton Papers.

The Evolution of PI System #16

at Appleton Papers

Overview

Story Begins with Custom Developed Quality Data Management System in 1976

PI System #16 Purchased from OSI in 1988 as 1,200 Tag Corporate Development System

Custom Developed Systems In Plant Replaced With Vendor Supplied Packages

PI System #16 Evolved To 40,000 Tags at the Heart of the Plant’s Process and Quality Information Systems

Appleton Papers Requirements

Quality Focus Customer Service Focus Many Differentiated Products High Value Products and Raw Materials Flexible Manufacturing Environment

Real-Time Process and Quality Information

On Operating Floor a MUST

Appleton Papers Background

Manufactures High Value Coated Papers NCR Carbonless ™ Thermal Specialty Products Coated Free Sheet

7 Manufacturing Sites In USA Driven By “Customer Focused Quality”

World’s largest carbonless paper producer NCR Paper* brand most recognized worldwide USA’s largest thermal paper producer An emerging coated free sheet producer

Peterborough

Harrisburg, PARoaring Spring, PA

West Carrollton, OH

Combined Locks, WIAppleton, WIPortage, WI

Portland, OR

Kansas City, KS

Newton Falls, NY

Los Angeles, CA

Atlanta, GA

Independence, KY

Albany, NY

Manufacturing FacilityDistribution Center

Over 800,000 tons of production 4,300 employees Over $1 billion sales revenue

Appleton Papers, Inc

Appleton Plant Background

Manufacturing Flexibility– Diverse Equipment Capabilities– Produces All API’s Product Lines

1050 Employees – 163 Salaried Employees– 887 Union Employees

1813 Products; Many Multiple Pass

Appleton Plant Equipment 3 Coating Kitchens

Over 200 Tanks

13 Production Coating Machines 24 Coating Stations 27 Scanning Gauges

31 Finishing and Converting Machines Calenders Rewinders Sheeters Trimmers

Control and DCS Equipment Measurex Allen Bradley WonderWare

Timeline

In the Beginning...

1976 - QCDMS Quality Control Data Management System

Scope of Lab Data Collection Quality Reporting

1980 - QCDMS Expansion Need For Process Data Revealed

Installed Interface Equipment to DCS For Limited Process Data Capture

Measurex “Data Freeway” on Coaters

The Door Opens For PI …

1988 - Need For Process Data Expands– New Installations and Upgrades Of DCS Equipment– Project Defined To Save ALL Process Data– Eight Years Experience Highlighted That Process Data

Needed To Be Coupled With Quality Data AND “Alpha” Data To Achieve Maximum Return

– Replacement For QCDMS Sought

1988 - OSI & PI System Explored– Corporate I.S. Performed Initial Evaluations – System #16 Purchased As Development System– Plans Developed to Supplement PI with Custom Developed

LIMS Application

Time Passes ...

1991 - “LIMS” Developed– Lab Information Management System – Developed By Corporate I.S. on VAX/VMS Platform– Planned Corporate Rollout Along With PI System– PI-Toolkit on VMS Used For Development– Used PI For Data and Specification Archive– Used RDB For “Alpha” and Relational Data– OSI Modified Real-Time SQC To Meet Appleton’s

Requirements

At Last …

1993 - System #16 Installed At Appleton Plant– PI Installed Simultaneously with LIMS– PI System Expanded to 40,000 Tags– Data Moved from QCDMS to PI and LIMS– New System Became Centerpiece Of Quality

Management and Process Optimization– QCDMS Scrapped

Black Hole No More ...

Value In Reporting Tools– Exception Reporting– Quality Certification Reports– Specification Derivation– Process Optimization Reporting

The Snowball Begins Rolling …

1994 - Development & Expanded Usage– Individuals Using System Increased– Departments Added To System

Culture Change …

PI Screens At Each “Work Center”– Process AND Lab Data Available to Machine Operators– Operators (Not Supervisors) Make Operating Decisions– More Sophisticated Tools Available

SQC Charts Historical Data Analysis LIMS Reports

Successful Implementation

Get Shop Floor Involvement!!– Graphics Screens Developed FOR Operators BY Operators– Floor Experts Taken Off Shift To Get Involved In Project

Available For Questions From Peers Continue To Maintain and Create Displays

– Process Engineers Insured That Data Was Accurate and Appropriate

Make System Part of Standard Operating Procedure– Quality Disposition (Ship / No Ship)– Process Troubleshooting

Always Look To The Future– Networked PCs and Printers Installed vs. “Dumb Terminals”

Constant Expansion ...

1995 - ProcessBook and DataLink Installed– Mountain Systems, Inc Assisted With Training

Primarily Engineering, Technical, and I.S.

– DataLink Immediate Value For Ad-Hoc Analysis

Analysis In Windows Environment

Expanding Needs …

Ease of Use Highlighted Additional Opportunities– Merging of Process and “Alpha” Data– Smarter Filtering of Historical Data for Startups

Opportunities Put Pressure On Custom Developed Tools

To Evolve At Pace With PI System

More and Better Tools …

1997 - GradeBook Installed– Packaged Software from Mountain Systems, Inc. – LIMS Replacement– Benefit From Continuous Improvement Of Software By

Vendor– Very Tight Integration With PI & Microsoft Tools– Improved Analysis Tools– Improved Specification Maintenance– “Grade Run” Data Management

Better Information = Faster Startups

GradeBook and PI - Analysis

Evolution Continues …

1998 - ProcessBook as ActiveX Container– Final Merge of Operator Views– First Time Variety Of Real-Time Process, Quality,

and “Alpha” Information Can Be Focused Into Single Display

– Asking Operators To Consider More and More Information

– “Smart Alarming” and “Display By Exception” Only Alternative

– Leveraging Microsoft Tools for Analysis and Reporting At Operator Level

Benefits …

Operator Empowerment Process Optimization

– Grade Change Improvement– Troubleshooting Ease

Systems Integration Lowered Learning Curve

In Summary …

PI Is Like Drugs– But Results Are Good– You Need A Few Pushers Around– The First Fix Is Free– Cultivate Addicts– Better Ones Are Always Being Designed– Just Say “YES”

Questions & Answers