This document discusses using big data and real-time analytics to improve efficiency and reduce costs in paper production. It outlines a plan to combine production, quality, cost, and materials data from various systems into a single big data application. This would allow analyzing actual production costs and quality against theoretical and historical benchmarks in real-time. The goals are to coach production staff to optimize efficiency, reduce costs by 1% or more, and potentially save over 50 million euros annually for paper companies. The proposal argues this could be done in-house at low cost using existing systems and tools.

1. Lauri Tapola
2014-01-11
Big Data in paper production

2. About me
 20 years experience in IT.
 M.Sc. in IT.
 Last 12 years in UPM paper business.
 Last 6 years in Global Mill Execution systems (GMES)
project.
 Responsible of reporting and production costing
systems from IT point of view globally.
 I know the systems in paper business.
 Especially production systems in paper production.
 Reporting and business intelligence tools.
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3. Current situation in paper
production
 Profits in paper production have smelted to
very low level.
 In order to grow our profits, we have to cut
production costs.
 Even 1% savings in production costs are tens
of millions in company level yearly.
 It’s possible to achieve those savings by
utilising IT systems efficiently.
 How to manage this?
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4. How to win in the future?
In theory
 We have to produce paper in the most
efficient and economical way.
 We have to be very quick and exact in
analysing production costs.
 We should be able to improve in
economical paper production.
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5. How to win in the future?
In practise
 We have to analyse actual production
costs as quickly as possible. (€/ton/grade)
 We have to coach our production staff to
use our systems in the best way.
 -> Team that plays together in the most
efficient way wins the game!
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6. What to do in practise
- Phase 1
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• We should combine:
• Productional data from production systems
• Quality data from Quality Systems
• Recipe data from Production Cost Management systems
• Electricity prices from Electricity price forecasting systems
• Data related raw material consumtions from Automation systems
•To get the report like below:

7. What to do in practise
- Phase 2
Mill: KAU PM: PM1
Grade: B84070 Run: 123021
Orders: 768765 754654 543765
Unit_PM: 954-00
Production:
Actual
Cost
Theor.
Cost
AveCost
last10r
AveCost
last10d
AveCost
last100d
Actual
Qual.
Theor.
Qual.
AveQual
last10r
AveQual
last10d
AveQual
last100d Action
Current: 98,3 100 99,5 99,7 100,2 106 100 103 105 102 Decrease ash by 5%
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• Actual production costs compared to theoretical and historical costs
• Actual quality compared to theoretical and historical quality
• Advises for better cost-efficiency in current production
• in phase 1, we should also enter the data in datawarehouse
• in phase 2, we can compare actual key figures (cost, quality) against
previous production figures.

8. What I’d like to do?
 Create that Big Data application
 Manage calculation of production costs
in realtime with quality indexing.
 Coach users
 Coaching vs training
 We should coach our employees like top
athletes to get world class results !
 When this is done we are the best in the
world in our business.
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9. Realistic earnings and
development costs?
 Earnings:
 Goal: Save 1% of raw material and energy costs
 at least 50 M€/year
 Costs:
 My salary = 0,1 M€/year.
 No other software/hardware/consulting costs if this
is done in-house and on top of current systems with
current or open software development tools!
 I believe on this!
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10. Current situation
- No combined Cost data with production data!
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Production Cost
management
Quality
management
Automation
systems
Production
Execution systems
 Usually companies are reporting key production properties
(efficiencies, costs) only afterwards;
daily, weekly, monthly, yearly with various tools

11. Future with Big Data system
- Combined Cost data with production data
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Production Cost
management
Quality
management
Automation
systems
We need a tool to manage cost-efficiency and quality in production
in realtime. (as quick as possible)
GMES - Production
Execution systems
Big Data PDI = ”Production data intelligence”
PDI

12. Thanks for watching,
if you are more
interested, please contact
me:
ltapola@gmail.com
+358 40 8362966