RockTenn, a leading North American producer of paperboard, containerboard, and consumer and corrugated packaging with sales of approx. US $2.8 billion, has been an OSIsoft Enterprise Customer since 2007. Since the initial PI deployment, RockTenn’s paper mills have made numerous process improvements due to better visibility into our processes. This presentation discusses the next phase in using PI data to quantify and improve process capabilities on one of the RockTenn paper machines. The project began as a Six Sigma initiative focused on reducing variability in paperboard caliper, basis weight, and moisture. Sources of variation were identified and control plans developed for fiber management and refiner control. PI tools are used to provide people in all areas of the mill with real time feedback on fiber furnish, refiner performance and process capabilities. The ease of access to PI data is critical to sustain these improvement gains.
Matt Corcoran is a third generation papermaker working in the recycled paperboard field who began working with PI in 2005 as a part of RockTenn’s pilot program at the uncoated paperboard mill in Chattanooga, Tennessee. Now he is the PI Power User for the Chattanooga Mill.