How Sam Operational Solution works as a virtual supervisor on tissue converting lines

Tissue converters face constant and increasing pressure on all sides, from product quality to sustainability expectations, while at the same time facing the challenges of a skilled labor shortfall. For example, a recent study reported that even as unemployment rates in the U.S. nearly doubled the number of available workers, 77% of manufacturers said they expected ongoing challenges attracting and retaining workers in the years to come.¹

These competing pressures add complexity to monitoring requirements on tissue paper machines, making it even more difficult to identify and make the many adjustments needed at critical points along the production line. These issues are constant in a manufacturing process that involves the inherent inconsistencies of organic raw materials.

While initiatives like the World Economic Forum’s Reskilling Revolution seek to boost education and job skills for a billion workers over the coming decade, it is clear that manufacturers must also look to technology to help close the skills gap and support productivity.² The limited availability of skilled workers, alongside rising demand to achieve greater overall equipment efficiency (OEE), highlights a need for tissue converters to be able to rely on technology innovations to achieve operational goals, including:

• Improving product quality
• Avoiding manufacture of non-compliant products
• Increasing efficiency
• Reducing product waste

Valmet’s Sam Operational Solution puts sensor technology to work at critical points throughout the various process steps along the tissue converting line, constantly measuring and monitoring materials, products and equipment performance at the points where deviations can occur.

The proactive automated measuring and monitoring of Sam Operational Solution enables prompt intervention, preventing the production of large volumes of out-of-specification product — avoiding the production of waste.

Sam systems’ sensors and automation technologies monitor machine performance and product quality according to parameters established by the operator using the HMI (human-machine interface) panel. Each Sam solution is designed to supervise and monitor a specific segment of a tissue converting line to improve performance, quality and consistency;

• Sam Log measures key log characteristics including diameter, firmness and weight
• Sam Perf detects the correct approach of perforation blades and monitors for blade wear

While each Sam solution delivers advantages to the line operator from within its segment of the converting line, the complete Sam Operational Solution works holistically to deliver even greater peace of mind and risk reduction. Even in unforeseen production circumstances (such as new raw materials) or with less experienced operators, Sam helps optimize quality, production, efficiency and machine performance, delivering a competitive advantage to the converter.

Every critical point in the tissue converting process has the potential to contribute to optimal product quality and improved OEE, and Sam Operational Solution’s “virtual line supervisor” helps converters identify and seize those opportunities. Contact Valmet to learn more.

 

SOURCES
¹ Deloitte, US Manufacturing Skills Gap Could Leave As Many As 2.1 Million Jobs Unfilled By 2030, Deloitte and The Manufacturing Institute Study Finds, May 4, 2021.
² World Economic Forum, 3 reasons manufacturing in 2021 will focus on connecting workers, April 30, 2021.