Improved planning accuracy for Metso’s Roll Factory with Delfoi Planner

Metso Paper’s Tampere-based roll factory produces tube rolls for paper machines for the group’s internal customers. Prior to the implementation of Delfoi Planner, the data were scattered across different systems and combined in Excel tables that were difficult to manage and analyze. The objective was to reduce lead-times and the work in-process, i.e. to improve productivity. This also improves delivery reliability.

"Our operations are very fast-paced and communication plays a central role in their execution. We used to store and handle data via several different user interfaces – and there was no uniformity. Delfoi Planner is a comprehensive system that supports Metso’s process-based operations. This is something that the traditional systems couldn’t do", says Jari Yli-Välitalo, the manager of the Tampere Roll Factory.

"Delfoi Planner facilitates project management because the entire process from sales to production is integrated into one system", says the workshop manager Markku Lingman. "Our main objective was to collect all operations under one umbrella. It is of great importance to us to have uniform data that is accessible to everyone in real time", Jari Yli-Välitalo continues.

Project team at Metso Paper.

Capacity Management at the Accuracy of One Hour

Prior to Delfoi Planner, capacity and load calculations at the roll factory were performed using Excel, which enabled to monitor the active capacity and load at the weekly level. Delfoi Planner renders it possible to monitor rough capacity at the daily level and finite capacity at the accuracy of one hour. The system has been subdivided into cells according to the factory layout.

As far as finite capacity is concerned, several different plan scenarios can be created and compared in order to find the best alternative. Only after that will the tasks be moved to queues.

"Improving the accuracy of production planning was a key factor for us. If, for example, someone working in the production unit is on sick leave, the supervision unit will immediately inform the production planning engineer and enter the data in the resources calendar, which enables us to use the Planner to simulate the impacts of the sick leave on production and, in the event of longer absences, decide whether subcontractors should be hired to compensate for the absence", Markku Lingman explains.

"The Planner comes in handy when handling overload situations as well. It is possible to view a visual representation of the capacity and load for a chosen period of time at the resource level. A pop-up window indicates the project the machine is being used for. The Planner also provides factory-specific capacity graphs for the management, for example", says production development engineer and quality manager Mika Lingman.

"Visually the Planner is very clear and easy to use. Each machine can be managed on the basis of the week view of the calendar, or a longer time period if desired. The calendar also features machine limitations – such as maintenance and shift-models – which the simulation function takes into account and moves the work automatically to another machine. The utilization rate shows the number of queues and the projects in the queues. Simulation also renders it possible to plan what action to take in exceptional cases. In finite capacity, tasks can be moved to an earlier or later point of time", Mika Lingman explains.

"Simulation enables us to predict the impact of changes and take action in advance, not afterwards", says Jari Yli-Välitalo.

"The Planner has provided us with proper tools; we didn’t, for example, have real-time schedules for each machine at the workshop before. And now we can calculate the route of each individual roll: the machines through which it passes and the phase in which it is at any given time. We also acquire more profound knowledge of what constitutes reliability of operation when we know which rolls belonged to a certain delivery, which ones were late, how much and why", Mika Lingman continues.

"The biggest change has taken place at the workshop. Every work station has a computer on which uniform data is at everyone’s disposal. Before Delfoi Planner was adopted, the supervisors working at morning and evening shifts sometimes gave contradictory instructions, but now the finite capacity and queues are visible to all. As far as motivation is concerned, it is important that employees can see what kind of work is coming up next in the queue. If the first task in the queue cannot be carried out for some reason, it is possible to move on to the next one", Markku Lingman explains.

"This tool is indeed handy", confirms the production management engineer Toni Kyösti who uses Delfoi Planner on a daily basis in his work.

Adapted to Metso needs

Metso Paper Inc. provides comprehensive solutions for the pulp and paper industry and is the market leader in large-scale and fast-operating paper machines.

"There are not many similar systems available that would meet our needs", says Jari Yli-Välitalo.

"This has been a large project for both Delfoi and for us. The changes and updates have been implemented rapidly. The project has been carried out as genuine cooperation: a solution to problems has always been found and communication has been open and fair. Delfoi is truly dedicated to this project. The system also has potential to meet our future needs", Markku Lingman says.

"Cooperation with Delfoi has been smooth. We have exchanged ideas in meetings, on the phone and via e-mail. Needs and wants have been met", Mika Lingman adds. Close cooperation is crucial in implementing a customized solution in order to achieve a solution that fulfills the expectations", says Jari Yli-Välitalo.

Delfoi Planner – Impacts and Benefits

Data is uniform and at every user’s disposal in real time
Simulation renders it possible to predict the impacts of changes and take appropriate action in advance
Simulation enables optimization of capacity and avoidance of overload
Production capacity and load of each individual machine can be monitored at the accuracy of one hour or even minutes if needed
In exceptional cases work can easily be moved from one machine to another
Improves delivery accuracy
Reduction of lead times and the work in-process increases productivity