Iggesunds Paperboard installs digital video analysis
recently introduction of video analysis equipment at its production
facility has significantly improved efficiency.
The system was installed in order to achieve better quality and production benefits. Machine stoppages cost money, and the firm believed that this could be kept to a minimum through the application of cutting edge technology.
The installation consists of a digital camera system that records onto hard disk. Over 20 cameras located along the length of the board machine record events within the most recent four-minute time period, enabling the operator to search for deviations and their causes.
"When a board machine stops due to a web break we have only one priority - to get things up and running again as soon as possible," said Daniel Thor, production manager for the KM1 board machine at Iggesunds Bruk. "A camera system provides support in the decision-making process, making it easy for the operator to pinpoint the cause of the break and avoid the same problem arising again."
Camera surveillance systems are nothing new, but Iggesunds has found that digital technology and hard disk recording is much faster than conventional systems. When a web break occurs, staff can take action immediately with the aim of restarting production as soon as possible.
By using the camera system as an analysis tool the cause of the break can be quickly determined and there is less risk of trying to restart the machine without first having fixed whatever caused the stoppage.
"Web breaks mean a drop in production but they also cause quality variations in what is produced," said Thor. <>"Reducing the number of web breaks is one of the most important measures we can take to increase quality consistency. That's why we prioritise them at all of our production follow-up meetings."
Iggesunds claims that within a short period of time, the use of the camera system at KM1 has led to a more reliable classification of the causes of web breaks. It has also caused a noticeable reduction in the number of breaks and a resulting increase in output.
The camera system records breaks in the web while a complementary system for the detection of holes and surface defects starts recording when such a flaw occurs. Using both these systems in conjunction is important for increasing knowledge about what is happening inside the board machine.
Being able to determine the causes of these problems not only improves production volumes and quality consistency. The system also provides more reliable indications of where to focus maintenance for maximum effect - which in turn makes it possible to reduce maintenance costs.
"During the past month we were able to significantly reduce the number of web breaks," said Thor. "Our investments in hardware and knowledge expansion will be repaid in greater production volumes and improved quality. And the knowledge we gain about what's happening inside the machine is crucial to all our R&D work."
