Mill Variability Optimization Programs, 1993 Process Control, Electrical & Information Conference Proceedings

W.L. Bialkowski

In 1984 pioneering efforts began to focus the attention of the pulp and paper industry on optimizing product uniformity and mill efficiency through the use of modern variability reducing methods for process control design and tuning. This was done through an intensive series of mill variability audits together with training programs for technicians, engineers and managers. About 100 audits have been carried out and over 1500 people have received training The audits revealed that process variability in most mills was much higher than expected, with a resulting impact on product uniformity and mill efficiency. The training programs revealed that virtually none of the engineers and technicians who enrolled possessed a functional understanding of the general principles of automatic control prior to the start of training and that managers had little concept of the true capabilities of process control activities.

This work sparked the initiation of mill variability optimization programs in about a dozen mills. All of these programs have shown initial success in improving product uniformity and efficiency. In spite of this, most programs have exhibited considerable difficulty in maintaining momentum while others have been defeated and abandoned. The root cause for this dificulty is both structural and cultural within the industry, which places tons of production above all other priorities, with little or no provision for sustaining continuing improvement programs over the long term.

The main barrier to progress is not technological, but rather a deep seated lack of understanding by industry management of the true nature of process control and its potential to enhance competitiveness. This leads to an inability to provide the leadership necessary for bringing about the organizational and cultural changes needed to meet the challenge.