Incorrect selection of winding parameters
Winders run different grades, each requiring a specific set of winding parameters (torque, nip , tension), to produce rolls with optimal structure and free from defects.
The winding parameters are either selected automatically or manually by operators.
Detection & Corrective Actions
Out of the 410 Key Performance Indices (KPI’s) we calculate on each set, several are dedicated to monitoring the winding parameters levels and profiles.
Our automated analysis system sent an automated notification to the mill and alerted our experts on an abnormally low drum torque differential level.
The diagnostic indicated that the abnormal level and profile occurred after a change in winding parameter recipe selection.
The operator was then asked to toggle the recipe selection, this restored the correct levels and profiles.
Concurrently we asked the mill to intercept the rolls produced and test them (Smith needle). The 26 sets produced with these wrong settings had insufficient tightness, the mill decided to cull them.
Outcome & Financial Benefits
Detecting this issue in a timely manner avoided sending the defective rolls to the mill’s clients. Had this problem gone undetected, it would have been reported by clients accompanied with substantial claims.
The timely detection by SPN’s service of that specific anomaly resulted in:
– Savings of more than $450,000 US dollars in lost revenue
– Avoidance of a downgrade of the mill in supplier ranking
Abnormally Low Drum Torque Differential Profile