New Approach of Process Optimization by Analysis of Plant Big Data

―Cooperative Optimization Control of Stock Preparation and Paper Making―

Abstract

In recent years, as for manufacturing industry of Japan, especially in the process manufacturing indus tries of the energy-intensive industry, energy consumption rate are increasing and upward trend due to trend shifts from mass production to small varieties and variant variable production etc. Therefore, the need for a smart factory energy management system（FEMS）that guarantees productivity is increasing.

Although optimization of individual facilities and individual processes are being carried out through our company's improvement activities at factory production sites, it has been found that optimization by the co operation between the adjacent production processes and optimization by the cooperation between the pro duction process and the power process have not been satisfactorily done yet.

We conducted a detailed survey through trial test at the target factory to determine the extent of ener gy saving potential through cooperative control between a production processes. In planning and realizing these remedial measures, it is necessary to efficiently collect and analyze so-called plant big data in produc tion processes. At the same time, it is required to perform appropriate optimum control and pre-simulation. From these points of view, we confirmed the effectiveness of “the Cooperative optimization tool between pro cesses”．

Moreover, as an example of cooperative optimization between adjacent processes, we applied a new con cept of feed forward control to color and ash control between stock preparation process and paper making process and confirmed the possibility of energy saving by 50% compared with conventional manual opera tions.