Paper360 - March/April 2018 - 22

These programs allow for exceptionally
rapid cleanup of inaccurate data values. Special
events such as outages can be easily eliminated from the data. For the indent example
mentioned here, the data-cleansing (which
required several weeks when performed manually with spreadsheets) was easily accomplished in a couple of hours.
These programs have also been used for
rapid analysis of long-term trial data. A specific example involved the impact of three different types of refiner plates on paper quality.
A process engineer was able to obtain plate
run-life data over a two year span in less than
15 minutes, and use this data to categorize
paper quality data by paper grade and plate
pattern. As may be seen in Figure 2, there are
substantial differences in plate life among
the plates tested; more significantly, statistically significant basis weight differences were
also detected. This is actionable information
guiding operations toward a quality and cost
improvement opportunity.
ENGINEERS NEEDED
The advent of these new data acquisition
and analysis tools has not eliminated the need
for process engineers with a deep understanding of the process. The tools are developing
for modeling and correlating various operating parameters over the entire mill-but,
of course, correlation may not correspond to
causation and the models may be inaccurate.
Experienced engineers familiar with the processes being evaluated must still interpret and
act on the signals discerned.

For example, Figure 2 shows significantly
different run-hours among the refiner plates,
but an engineer still had to determine whether
there were any special events that impacted
the data, evaluate the impact of the different
plates on fiber and resulting paper properties,
and estimate the overall economic impact of
the different plates. Once these questions were
answered, the engineer could then determine
the total cost of ownership for each style of plate,
identifying a cost optimization opportunity for
the mill. In the example depicted in Figure 2,
these questions were rapidly answered.
NEW TOOLS NEED NEW METHODS
These new tools provide enough computing
power to allow mill engineers to see data trends
across the entire mill and over several years.
Unfortunately, when dealing with data-sets of
this size, in conjunction with the computing
power necessary to successfully and rapidly
correlate these types of exceptionally large data
sets, old methods of analysis and statistical
manipulation must be replaced with new and
improved capture and analysis techniques.
For instance, in the paper indents example2,
a significant amount of effort was spent to
determine times of poor operational performance and compare those "poor" times with
periods of "good" operational performance.
With these new tools, it is important not to
review data only from "bad" times, however
defined, as compared only to "good" times.
Data from intermediate operating condition times contains valuable signals as well.
Therefore, the objective of data-sorting is to

define realistic parameter ranges and eliminate only truly bogus values.
A cautionary note: It is no longer appropriate
to assume normal distributions of data, as has
been common; with so much data, we know
the distribution. We know the process has been
altered with both manual and automated control parameters, the data distribution is specifically not "normal," and different statistical
approaches for analysis of these non-normal
data are required.
ON THE RAGGED EDGE
The use of Big Data is on the cusp of becoming
a powerful tool in the identification and elimination of long-term, systematic operational issues
within the pulp and paper industry. Big Data
techniques allow engineers to determine the
true interactions among different areas of the
mill, to highlight behaviors in one part of the
mill that have negative or positive impacts upon
other parts of the mill, and to act as indicated.
To fully realize the potential of Big Data, the
industry must develop and embrace significant
paradigm shifts in data capture, sorting, analysis
protocols, and statistical tool packages.
Improvements in computing power, plus software programs that allow data manipulation
and cleansing, have recently supported performance of several limited Big Data studies-usually with positive impacts to the mill's bottom
line, and always resulting in new insights. Use of
non-normal statistical techniques and improved
engineering understanding of Big Data analysis
protocols and methods should lead to significant
increases in performance. We are truly at the
ragged edge of the Big Data revolution.
The author gives special thanks to Kathleen
Bennett and Humphrey Moynihan for editorial insights and improvements to this article.
REFERENCES:
1. M. Sandin, "Operational Data Helps Mills Meet
Challenges," Paper360°, Nov/Dec 2017, pp. 34-36.
2. J. Fu, P.W. Hart, "Leveraging Mill-Wide Big Data Sets
for Process and Quality Improvement in Paperboard
Production," TAPPI Journal, Vol. 15, No, 5, 2016,
pp 309-319.

Peter W. Hart is director, fiber science and technology for WestRock in Richmond, VA. He and
his co-authors were awarded the 2016 TAPPI
Journal Best Paper Award for his research paper
"Leveraging Mill-Wide Big Data Sets for Process
and Quality Improvement in Paperboard
Production," cited in this article. Reach Hart
at peter.hart@westrock.com.
22
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Table of Contents for the Digital Edition of Paper360 - March/April 2018

Setpoint
Over the Wire
The Importance of Safety Training
Data & Decision Making
RISI European CEO of the Year: DS Smith’s Miles Roberts
Buckman’s Junai Maharaj on ‘The Art of the Possible’
Fapajal Tissue: Old, New & Customer-Centric
Progroup Turns 25
PIMA, Paper360° Co-Host Executive Panel
Creating a Lignin Culture
Benefits of Drive-Through Design
Sustainability as Business Leverage
CIPTE Show Highlights Innovation and Sustainability
TAPPI Journal Summaries
Leadership in Maintenance: Where Do We Start?
As a New Reliability Engineer, Are you Confused About Your Role?
R&M Tips
Paper and Board Have Key Roles in the Future of Packaging
Global Paper and Paperboard Demand Growing Despite Declines in Graphic Paper
PPI Awards Showcase Industry Excellence
TAPPI News
ASPI News
Index of Advertisers
Paper360 - March/April 2018 - intro
Paper360 - March/April 2018 - ebelly1
Paper360 - March/April 2018 - ebelly2
Paper360 - March/April 2018 - cover1
Paper360 - March/April 2018 - cover2
Paper360 - March/April 2018 - 3
Paper360 - March/April 2018 - 4
Paper360 - March/April 2018 - 5
Paper360 - March/April 2018 - Setpoint
Paper360 - March/April 2018 - 7
Paper360 - March/April 2018 - 8
Paper360 - March/April 2018 - Over the Wire
Paper360 - March/April 2018 - 10
Paper360 - March/April 2018 - 11
Paper360 - March/April 2018 - The Importance of Safety Training
Paper360 - March/April 2018 - 13
Paper360 - March/April 2018 - Data & Decision Making
Paper360 - March/April 2018 - 15
Paper360 - March/April 2018 - 16
Paper360 - March/April 2018 - 17
Paper360 - March/April 2018 - 18
Paper360 - March/April 2018 - 19
Paper360 - March/April 2018 - 20
Paper360 - March/April 2018 - 21
Paper360 - March/April 2018 - 22
Paper360 - March/April 2018 - 23
Paper360 - March/April 2018 - 24
Paper360 - March/April 2018 - 25
Paper360 - March/April 2018 - 26
Paper360 - March/April 2018 - 27
Paper360 - March/April 2018 - 28
Paper360 - March/April 2018 - 29
Paper360 - March/April 2018 - 30
Paper360 - March/April 2018 - 31
Paper360 - March/April 2018 - RISI European CEO of the Year: DS Smith’s Miles Roberts
Paper360 - March/April 2018 - 33
Paper360 - March/April 2018 - 34
Paper360 - March/April 2018 - 35
Paper360 - March/April 2018 - Buckman’s Junai Maharaj on ‘The Art of the Possible’
Paper360 - March/April 2018 - 37
Paper360 - March/April 2018 - 38
Paper360 - March/April 2018 - 39
Paper360 - March/April 2018 - Fapajal Tissue: Old, New & Customer-Centric
Paper360 - March/April 2018 - 41
Paper360 - March/April 2018 - 42
Paper360 - March/April 2018 - 43
Paper360 - March/April 2018 - Progroup Turns 25
Paper360 - March/April 2018 - 45
Paper360 - March/April 2018 - 46
Paper360 - March/April 2018 - 47
Paper360 - March/April 2018 - PIMA, Paper360° Co-Host Executive Panel
Paper360 - March/April 2018 - 49
Paper360 - March/April 2018 - Creating a Lignin Culture
Paper360 - March/April 2018 - 51
Paper360 - March/April 2018 - 52
Paper360 - March/April 2018 - 53
Paper360 - March/April 2018 - Benefits of Drive-Through Design
Paper360 - March/April 2018 - 55
Paper360 - March/April 2018 - Sustainability as Business Leverage
Paper360 - March/April 2018 - 57
Paper360 - March/April 2018 - CIPTE Show Highlights Innovation and Sustainability
Paper360 - March/April 2018 - 59
Paper360 - March/April 2018 - TAPPI Journal Summaries
Paper360 - March/April 2018 - 61
Paper360 - March/April 2018 - 62
Paper360 - March/April 2018 - 63
Paper360 - March/April 2018 - 64
Paper360 - March/April 2018 - Leadership in Maintenance: Where Do We Start?
Paper360 - March/April 2018 - As a New Reliability Engineer, Are you Confused About Your Role?
Paper360 - March/April 2018 - R&M Tips
Paper360 - March/April 2018 - Paper and Board Have Key Roles in the Future of Packaging
Paper360 - March/April 2018 - 69
Paper360 - March/April 2018 - Global Paper and Paperboard Demand Growing Despite Declines in Graphic Paper
Paper360 - March/April 2018 - 71
Paper360 - March/April 2018 - PPI Awards Showcase Industry Excellence
Paper360 - March/April 2018 - 73
Paper360 - March/April 2018 - 74
Paper360 - March/April 2018 - 75
Paper360 - March/April 2018 - 76
Paper360 - March/April 2018 - 77
Paper360 - March/April 2018 - 78
Paper360 - March/April 2018 - TAPPI News
Paper360 - March/April 2018 - 80
Paper360 - March/April 2018 - ASPI News
Paper360 - March/April 2018 - Index of Advertisers
Paper360 - March/April 2018 - cover3
Paper360 - March/April 2018 - cover4
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