The Need for a System Approach to the Application of New Technology: Creating Value Through Product Improvement and Process Efficiency, 2003 Spring Technical Conference Proceedings

Paper machines are complex systems with increasing operator reliance on control systems. In many cases, interactions occur from seemingly unrelated events on a paper machine. Over time these combine to create conditions that are vastly different in outcome from those originally intended. The need for good data gathering and analysis is crucial in this event. It is often the case that when a new piece of equipment, papermachine clothing or process change is applied to a paper machine the expected benefits do not appear to materialize in the way hoped for originally. In other cases, problems present themselves in unexpected ways or the changes provide benefits in other areas of the operation. An example of this might be a change in conditions in the forming section, headbox consistency for example. In itself this change should give direct benefits to machine performance. However, if trials are occurring in the press section at the same time the effects can become difficult to track without the correct measurements or data analysis in place.

Reliance on control systems is not in itself a problem but all too often this reliance takes the place of more practical, hands on experience of equipment and how to manage these resources to maximize performance. A simple example of this might be a furnish change on a machine in order to reduce costs or alter sheet properties. The effect of this on press fabric performance can be considerable, leading to serious reduction in machine efficiency if all other parameters are left constant, even if the change is small. A subtle change in press fabric design and/or a change in the cleaning and conditioning on the machine can easily accommodate this type of change.