mondi steti’s journey to operational excellence with the

© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015

Presented by

Mondi Steti’s Journey to Operational Excellence with the PI System Infrastructure

Ing. Miroslav Škrabánek


Welcome in Prag!

Did you visit nice places in old parts of Prag? Don’t hesitate!

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King’s towns & Štětí

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Mělník First vineyards with vine from France in 14.century

– Charles IV.


Štětí

10 000 citizens now

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Town was founded 1312


Company History since 1992

Privatization & Restructuring (SEPAP)

1992 1993 1995 1997 2000 2004 2008 2009 2010 2014 2015

Start up new cooking plant-SB

Ownership AssiDomän & Stratton SEPAP,a.s. & SEPAP Štětí a.s.merger

Full ownership (91%) of AssiDomän Sale of ROTO a.s. to Norske Skog

Mondi Ownership

CR entry into EU

Re-purchase ROTO

New PM6

New PM7

PM3 rebuilt

New PM6 Coater and Finishing

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Mondi Group

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•We are an international packaging and paper Group, employing around

25,000 people across more than 30 countries.

•Our key operations are located in central Europe, Russia, North America and South Africa.

Corrugated

Packaging

Fibre Packaging

Industrial Bags

Extrusion Coatings

Advanced Materials

Consumer

Packaging

Consumer Goods Packaging

Uncoated Fine

Paper

Uncoated Fine

Paper

Containerboard

Pulp

Containerboard

Packaging Paper

Sack Kraft

Paper

Speciality Kraft

Paper

Europe &

International (E&I)

Division

South Africa

Division


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Mondi Steti

PM 7

Pulp

Recovery Energy Dept.

Water-treatment Plant

Mondi Bags

Mondi Coating

Woodyard

Neograph a.s.

PM5

PM1

Dryer

PM3,6 Coater and Finishing

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© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015 8

Key Highlights 2014

Annual production in th. tons 523 (100 trucks/day eq.)

Turnover in M€ 336

Total Assets in M€ 479

No of employees 634


-

100,000

200,000

300,000

400,000

500,000

600,000

-

500

1,000

1,500

2,000

2,500

3,000

Pro

du

cti

on

(to

n)

Hea

dco

un

t

headcount

production

Headcount and production development


● Market bleached pulp

● Sack kraft paper

● SF Paper

● Machine glazed papers

● Recycled containerboard

Our products


Bleached Pulp

High strength of fibre and high tear strength.

Excellent for reinforcing purposes.

Magazine papers (LWC, SC).

Kraftpapers.

Fine- and speciality papers.

Capacity 150 000 t/y


PM 1, Bohemia Liners

Liner board is used in corrugated boxes.

The board is two-ply and fibers range from 100%

kraft pulp to selected secondary fibers.

Capacity 110 000 t/y Substance 115 – 200 gsm Width 4400 mm


PM 6 & 3, Machine Glazed Paper (MG)

Light / medium-weight paper where one side is polished and has high gloss and back-side remains matt with rough surface.

End-uses are various packaging, protecting and lamination applications.

Capacity 79 000 t/y Substance 28 - 120 gsm Width 4560 mm


PM5, Sack-kraft and MF kraft paper

Manufacturing sack paper (standard, semi-extensible). End-use: paper sacks for powder material wrapping

Capacity 200 000 t/y Substance 70 - 110 gsm Width 6 400 mm


PM7, Sack-kraft White, SF White

Capacity 155 000 t/y Substance 50 - 120 gsm Width 6 300 mm

Manufacturing White sack paper (standard, semi-extensible). Smooth finished White papers (calandered papers with perfect printability and gloss) End-use: paper industrial bags for powder material wrapping, shoping bags,lamination, FFS bags (for sugar, flour, rice, …)


Technological data in Mondi Steti

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• Data inputs o Online sources – DCS ABB, Siemens, Metso, Honeywell, • Valmet, Measurex, GE Fanuc, PLC’s…

o Offline sources – Manual inputs (lab&operating values), ISDL, MES, Emission&Immission, SAP...

Excel – unified forms


TIS – Technological Information System

1999 – team founded solving for technological data platform • OPC – unified protocol • Online vizualization – Iconics Genesis • Historical data – OSIsoft PI System • Excel – unified forms

Stage TIS I (2000-2001) • OPC servers • PI System database (10000 tags) • 1.set of tags created in June 2000 • PI DataLink (100 licenses)

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TIS – milestones

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1999 Team founded solving for technological data platform

2000-1 Stage TIS I

2009 PI Data Archive upgrade,

64bit Windows server 2008

+5000 licensed tags

2011 PI Data Archive migration to VMware

2012 Break decision – change of

visualisation to OSIsoft platform


TIS – „new age“

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2013 - Upgrade of PI Data Archive

- Starting with PI ProcessBook

- Buying 5000 licenses for tags

2014 - Buying PVS (PI Visualisation Suite)

- Creating displays in PI ProcessBook

- Starting with Asset Framework (AF) – making structure for production and SPCC (Single Process Control Chart)

2015 - Creating rest of displays in PI ProcessBook (in total >300 displays)

- Start using PI Coresight

- PI Coresight in tablets and smartphones


TIS – future

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- Upgrade of PI Data Archive to leverage „Future data“

- Tag licensing expansion to 30.000 tags

- Using future data for gas and electricity diagrams and prediction

- Train users for using AF and PI ProcessBook

- Complete structure of production lines in AF

- Start with Notifications


TIS – using

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Operators – online process monitoring together with trends of process values

Laboratory – entering lab values

Dispatchers – process monitoring for making decisions about production

Technologist – production & process balancing

Managers – monitoring production, using reports for making decisions


TIS – benefits

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- Helps making decisions on all levels

- Unified enviroment for all users

- One data source for Excel and other applications

- Simple and fast tools for balancing, counting etc.


Contact Information

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Ing. Miroslav Škrabánek [email protected]

Process control / TIS / PI system Manager

Mondi Steti a.s.

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mailto:[email protected]





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