Tissue Paper Line Speed Modulation for Temporary Stop Management

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Solution Overview

Problem

Current tissue paper production and packaging lines face inefficiencies due to temporary stops caused by consumable exhaustion and wear, leading to production losses and operational disruptions, as existing methods primarily rely on reactive adaptations rather than predictive measures to manage these events.

Innovation Solution

A predictive method for managing tissue paper production and packaging lines that anticipates temporary stops by adjusting production rates and accumulator levels proactively, using detection systems to forecast consumable depletion and wear, thereby minimizing the impact of these events on overall productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the production line operates continuously at high speed, then productivity increases, but temporary stops due to consumable exhaustion and wear cause production losses and operational disruptions

Engineering Contradiction:

Improveproduction speedVSAvoidproduction loss during stops

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The control system performs preliminary actions by detecting consumable levels and component wear conditions before they cause line stops. It proactively adjusts production rates and schedules maintenance activities during planned downtime, preventing unexpected interruptions and maintaining continuous operation at optimal productivity levels

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous feedback monitoring of consumable levels (parent reels, packaging films) and component wear (cutting blades, grinding wheels). This real-time data feeds the control system, which automatically adjusts production parameters and alerts operators before depletion or failure occurs, eliminating unplanned stops

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If reactive adaptation methods are used to manage temporary stops, then operational flexibility is maintained, but production losses occur due to lack of predictive measures

Engineering Contradiction:

Improveoperational flexibilityVSAvoidoverall productivity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts production rates based on real-time conditions of consumable levels and component wear. The control system modulates line speed and coordination between machines to optimize productivity while preventing stops, adapting operational parameters continuously rather than using fixed reactive responses

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10941012B2Method for managing production and packaging lines of logs of tissue paper and line using said method

Publication Date: 2021.03.09 FABIO PERINI SPA

AI summary

The method provides for detecting a temporary stop request by a machine of the line, for example to replace a member subject to wear or a consumable. In view of this stop, the speed of the line is modulated so as to increase, for example, the level of filling of an accumulator, and makes sure that the subsequent temporary stop has a minimum effect on the overall productivity of the line.