Voith Paper Do you know what your QCS really costs?
Do you know what your QCS really costs? High Total Cost of Ownership Keep your automation system in place: contract situation with the supplier, technical age, etc. Review reasons for your high costs You should replace your QCS system in order to produce more efficiently If you want to achieve production increases, you should replace your QCS Low Low Opportunity cost High After a detailed analysis of the accumulating costs and of the QCS system itself, recommended actions can be suggested High maintenance costs Costs due to downtimes As a QCS measurement system gets older the costs for repairs, spare parts and service contracts increase. Comparisons have shown that the extra costs generated by these systems are, conditional upon higher efforts, far above those for a new modern Voith LSC measurement system. For the most part, the availability and reliability of these old systems can only be sustained thanks to the tireless commitment of the maintenance and upkeep team, the laboratories and the machine operators. This high internal outlay ties up personnel and thus also funds. Systems for which the replacement parts have been discontinued by the manufacturer are a particular problem, as often the parts can only be obtained with difficulty or at great cost and throw an uncertainty factor into the entire production operation. High monthly service contracts with external partners ensure the status quo of the system, but put an enormous burden on the approved service and maintenance budgets. A breakdown of the scanner s measurement signals corresponds to the entire paper machine running as if on a blind flight. The result is unplanned shut-downs for service and maintenance and upkeep that thus involves production breakdowns. In addition, with older measurement systems the reliability of measurements for basis weight and moisture, for example, is much lower. The electronic and mechanical components used are approaching the ends of their service lives and thus break down more frequently.
Betriebskosten in über den Zeitraum von 5 Jahren Opportunity cost Cost for upgrades Downtimes Service costs (internal / external) Additional benefit: more productivity Purchace of a new Voith LSC system Anteilige Servicekosten Anteilige Investitionskosten Existing QCS Voith LSC system Opportunity cost High measurement accuracy which would be possible today due to modern technology (e. g., by use of silicon detectors) simply cannot be achieved with an old system. In the worst case, the result is production of many tons of broke per year due to qualityproblems. Due to technical progress in the area of quality measurement technology, not only do maintenance costs accrue, but also opportunity costs. Older measurement systems often no longer meet paper quality requirements. You cannot meet the high quality requirements of your customers, or, if so, only with difficulty. Your old quality control system has already exceeded its technical limits and can no longer be further optimized. Since you therefore cannot continuously produce the highest paper quality, this leads to an imaginary profit the opportunity cost. In the end, as a manufacturer you are stuck with this cost. Paper with poor quality can only be sold at lower prices in markets where there are lower requirements or fed back into the process as broke. Both are associated with financial losses. In addition, poor measurements also impact on quality controls because only what is detected by the measurement system can be controlled. 2 3
Use the advantages of a modern Voith LSC system Technical Features Use of semiconductor silicon detectors for basis weight measurement instead of ionization chambers. Your Benefit Higher signal-to-noise ratio than with ionization chambers and thus higher measurement accuracy. An XYZ compensation through matrix arrangement of the detectors is possible at any time. Data capture rate of 100 khz allows high traversing speed of up to 1.000 mm / sec. Detection of high-frequency variations and quicker control. Digitalization of sensor signals in the measurement head and transmission via field bus (CAN bus). Secure, trouble-free data transmission proven in the automobile industry. Defined data boxes for each actuator. Malfunctions in the cross profile of the paper web can be corrected in a more targeted fashion. Modular concept, each sensor in its own enclosure. Quick replacement on-site and thus minimized downtimes in case of service ( plug & play principle). All sensors in one measurement axis. Continuous reading in of measurement signals, since unnecessary pausing or traversing over the edge of the paper web is omitted. PC-supported field bus testing possibilities. Complete diagnosis of the sensor in the test rig also available offline.
The Voith LSC measurement system is distinguished by its tremendous reliability Stepwise upgrade is expensive in the end After a certain service life with measurement systems, mostly after discontinuation of the system, a point is reached where investments can only minimize the breakdown risk but not eliminate it. Critical parts of the scanner and the sensors often remain in the system. The replacement parts necessary for this are hard to get and expensive. Even if the measurement processing is modernized, the existing measurement principle remains unchanged. Consequently, the quality of the controls is also not comparable to modern systems. It therefore makes sense with older systems to consider a complete replacement of the existing system. In many cases, implementation is possible without an additional investment. The new system can be obtained through the monthly savings to be expected, through fewer breakdowns and through additional revenues due to production optimization. A step-by-step upgrade can be substantially more expensive in the end. Above all, you should ask yourself whether it makes sense in the long term to invest in a system that the manufacturer itself discontinued long ago. 4 5
Specific system analysis helps in detecting and eliminating weaknesses Discontinuation of the system Operating costs (euros/year) 0 5 10 15 Service life (years) After installation, the costs for a new QCS system are for a certain time constant and increase rapidly toward the end of the service life Exact analysis Even though a QCS is not built for eternity, in contrast to a paper machine, the company that operates it surely assumes that the system delivers reliable measurement data from the startup through the entire life cycle. Therefore an exact analysis of the quality measurement system and the overall operating costs is absolutely necessary. Our experience in many paper mills has shown that this is not always the case in practice. Some paper manufacturers struggle with downtimes of the overall production processes due to malfunctions of the quality measurement system or bad quality of their end product. This occurs especially with older systems whose manufacturers have already discontinued hardware and software components. The result is increased operating costs and losses in efficiency of the entire production plant, the cause of which is, in the end, the faulty existing automation system.
Identifying weaknesses We help you to ask the right questions by analyzing your existing automation system together with you. Automation experts from Voith Paper Automation will identify the weaknesses of the system directly at the paper machine and subsequently evaluate the resulting follow-up costs. In addition, a benchmarking of your system in comparison with similar systems will in the end show the potential for improvement that can be attained with a new QCS. Specific requirements If you decide that it is time to replace your quality measurement system, we will supply you with a reliable automation solution that is adapted to the specific requirements of your process. In addition, with a financing model that is tailored to you we will make sure that this change is also financially feasible for your mill. 6 7
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