Prod-IQ® – Production Intelligence

Higher Profitability by Intelligent Control Technology

www.siempelkamp.com
 Cut your
2

production cost
Exploit the potential of available data!

Siempelkamp’s Prod-IQ® – this name

stands for innovative process control
systems, covering production data
management, quality assessment,
maintenance and repair as well as
their interfaces to an ERP system. The
individual Prod-IQ® modules have
been developed on the basis of our
customers’ needs. For some years now,
Siempelkamp has been using and
constantly modifying these modules;
it has turned out that there still is significant saving potential contained
in our customers’ production cost! And this potential is exploited simply
by making full use of the information comprised in the plant data already
available. Today the system is indispensable for a systematic improvement
of a plant’s productivity. Originally developed for specific purposes of
the wood processing industry, Prod-IQ® has also proven its suitability
for other business segments such as plants for metal forming or for the
production of wood-fiber insulation board.

+ more uptime, less downtime

+ optimized material consumption, less waste
+ consistent product quality
+ faster provision of all necessary data at all the right places
 3

The basic concept Prod-IQ® provides up-to-date, reliable and need-based

Prod-IQ® is a modular design, comprising Prod-IQ.
basics, Prod-IQ.business, ­Prod-IQ.­quality,
­Prod-IQ.­maintenance. Siempelkamp also provides
additional specialties like the order module with ERP interface,
cost trending or lab system interface. Such diversity has
turned out necessary to answer the specific demands of our
customers individually and economically.
information on demand for the management, the quality
assurance team, the production planning team, the
technologists or the plant operators.
Benefits: transparency and comparability.
Since a comprehensive assessment of cost-efficiency always
bases on parameters like the kind and number of boards
produced as well as their respective grades, consumption
figures, machine downtime and rejects.

Data collection Material flow tracking

basics Collection of process data to enable
centralized storage in a data base.
Lab report containing the measured
values correlated according to time and
place of occurrence in the process flow.

Downtime collection/statistics Production Data Manager

Systematic detection of downtime Standard reports for evaluations of Config Manager
and its cause. production orders, shifts, days and months. Centralized system configuration for
data collection, downtime causes, etc.

Trending (online + historical) Siempelkamp-performance proof

Production data in the time-line In new plants: evaluations and daily …
diagram for process monitoring. reports that can be used for a certain
period of time.

business quality maintenance

+ licences for two Office PC + technological support + logic tree
+ customized reports + modeling + periodic maintenance
+ incl. Script editor + online quality forecast and + on-condition maintenance
(acc. to the specs) check + feedbacks (scheduled  /  unscheduled
maintenance + repair)
+ history

for extensions for other plant components for other plant types
options
+ order module with + sanding line / finishing line + transformer board plant
ERP interface + lacquering line + wood-fiber insulation
+ cost trending + short-cycle press board plant
+ lab interface ... + metal forming plant
... ...
4
basics
Standard module in all new plants

Owing to its modular design Prod-IQ® can be tailored to any specific targets and priorities.
Prod-IQ.basics – as its name suggests – is the basic module, which can be extended any
time.

Prod-IQ.basics contains the following elements: data collection and material flow tracking
for documenting the entire production process, important evaluation elements that
make the production process transparent, e.g., downtime detector, as well as standardized
reports of production orders, shifts, days or months, which exhibit all characteristic values
concerning plant output, dependability, consumption figures and product quality.

Prod-IQ.basics comprises hardware, software and the relevant engineering. The production
process of wood processing plants is documented in standardized reports and evaluations.
The system is a standard module in any new ContiRoll® and is activated during plant
start-up.

Process documentation
The cyclic collection of process data is a prerequisite for all
the functions. The data available in the process network are
read from the PLC via the OLE for Process Control (OPC)
interface. Prod-IQ.basics applies a time stamp to the
process values collected for each parameter and, depending
on their use, memorizes these values continuously as mean,
minimum, maximum or event values in a database. All
other Prod-IQ modules will base on this process image.
®
This enables trends, online evaluations or reports for flexible
periods of time.
It is even possible to include data from plant components
of other suppliers. The plant owner just has to make its
data available in the process network, using the standard
interfaces specified by Siempelkamp.

Database

Process network OPC

 basics 5

Teach-in using lab samples

The material flow tracking function correlates the process make online forecasts on the physical properties like raw
data of a lab sample to the time and place of occurrence. board density, IB, MOR, MOE, thickness swell or delamination
The system determines automatically when the mat has strength.
passed a certain measuring spot in the course of the process
as well as the production conditions then prevailing, taking
into account the production speed, bin filling levels and
transport routes. Prod-IQ.basics thus documents the
history of the product in the form of a lab report. The physical
properties will be assessed in the laboratory and afterwards
correlated to the process data. Prod-IQ® is thus taught
specific process conditions and the board qualities resulting
therefrom. This will be the basis for Prod-IQ.quality to

Material flow tracking with lab report

moisture of blended

internal bond (IB)

prepress pressure

bending strength
area mat former
weight-per-unit-

lab sample
frame 38 center
blending factor

main heating 1
CL-glue/furnish

main heating 5

spec. pressure
temperature

temperature
temperature
dryer outlet

CL-furnish

thickness

(MOR)
infeed
...

...

170.90 8.60 6.30 27.90 128.20 227.30 195.60 50.19 19.44 0.43
... ... ...
°C % % kg/m² bar °C °C bar mm N/mm²
10:00:00

12:00:00
7:45:00

9:53:19

9:56:26

9:57:17

9:57:31

9:58:27

9:59:30

9:59:38

9:59:55


...

...

...

1 dataset

Production order evaluation Evaluations of shifts, days and months

The essential data of a production order such as board type, Prod-IQ.basics sets the shift changing times using the
quantity produced, uptime and downtime as well as con- system’s shift manager. Shifts and days will be automatically
sumption figures are summarized in a clear production order changed. A shift report contains data on shift code, shift
report. This report is immediately on hand, facilitating group, shift leader as well as the quantities produced, the
judgment on the technical and quality-related parameters production orders, uptime and downtime as well as the
of a production order. consumption figures relating to glue, wood, energy and
rejects. The daily report summarizes the figures of all the
shifts of a day, while the monthly report summarizes the
figures of all the days of a month.
6 basics

Production Data Manager

The Production Data Manager is a tool for the plant operator to access flexibly all
characteristic values on uptime/downtime and consumption figures, product quality
as well as all standardized MS Excel reports on production orders, shifts, days or Up-to-date information
months.

Historical
information:
- production order
- shift
- day
- month
(can be exported
to Excel)

+ creation of reports
Details:
- downtime
- consumption figures
- ...
including editor for corrections

The Production Data Manager comprises all optional representations of the evaluations
contained in Prod-IQ®. The representations divide into “Actual” and “History” for
production orders, shifts, days and months. In addition, the Production Data Manager
contains downtime statistics views and report management views.
 basics & business 7

Downtime collection and statistics

Systematic analyses of downtime aim at identifying preventable failures and their causes. To this end,
Prod-IQ.basics collects automatically all downtime occurred. The operator assigns standardized reasons
to each downtime. The downtime statistics system will then evaluate and edit the data in the form of tables
and bar charts. A weak-point analysis will follow to define adequate actions. The success of such actions,
in turn, can also be measured by Prod-IQ®.

+ cyclic detection of all process data

+ comprehensive documentation of the product history
+ precise downtime collection and fast remedy to any downtime
+ detailed, clear visualization

business
Individual evaluations and Office licences

Prod-IQ.business customizes the standardized evaluations and reports contained in

Prod-IQ.basics and provides additional licences for Office workstations. The system
uses predefined scripts (programming language: C#.NET) for the reports and the
evaluations, memorizing them in the Script editor. The Prod-IQ.business package
comprises the development licence as well as any support necessary to enable the
customer to adjust the reports whenever required.
8
quality
Online quality forecast system

The material flow tracking unit integrated in Prod-IQ.basics correlates the production
conditions and the resulting product qualities. Prod-IQ.basics assesses the processing time
of the furnish and the prevailing production conditions at several measuring spots within
the production system. Afterwards the laboratory will determine the pertaining physical
properties and relate them to the process data. Prod-IQ.quality, which is also well known
by the brand name of SPOC, will base on these data for further analyses.

Prod-IQ.quality is a comprehensive system, enabling online quality forecast of the essential

board properties such as raw board density, IB, MOR, MOE, thickness swell and delamination
strength.

Online quality control

After a teach-in phase of about six months, the data are used for a mathematical-statistical process
model, which is then made available. That means Prod-IQ.quality will base on the current process
settings, computing a quality model online and display the resulting trend. In addition, the system
will determine the minimum quality reserve required under the prevailing process fluctuations
in order to comply with the acceptable quality limit (AQL). Besides, Prod-IQ.quality provides
comprehensive information, offering technological support right from the start (plant comparison,
MFT trending, process monitoring).

Quality forecast
Necessary
quality reserve
AQL

Reduction of the raw board density of a particleboard by approx. 5 kg/m³ within 30 minutes
 quality 9

Forecast accuracy
Prod-IQ.quality (SPOC) enables to compute reliably the physical properties of a board
parallel to its production. This includes for example

Raw board density 99 %* MOR 95 %* Delamination strength 95 %*

Internal bond 95 %* Thickness swell 95 %*
*average forecast accuracy during operation of an MDF, particleboard or OSB plant.

Saving cost by reasonable quality reserves

The online quality check and the knowledge of the quality reserves actually required ensure to
maintain a precisely defined quality level. The operator may respond directly to any deviation from
the defined figures.

Stable production will result in consistent product qualities. Consequently, owners of wood processing
plants were able to realize material savings of 2.5%* after the online quality check had responded to
excessive quality reserves. According to our experience, those plant owners were also able to increase
their output of 1st grade board by 1 to 2%* and their production speeds by 3 to 5%*.

*Those data were retrieved from plants in operation.

Necessary quality reserve

Board properties

Quality level

Expensive quality reserve

without SPOC

with SPOC Necessary quality reserve

Quality limit

t
10 quality

Prod-IQ® = Cut in cost

Experience values
Savings Value Notes
from to
Systematic downtime analysis
Downtime reduction in % 1.5 1.5 2.5
 faster trouble shooting

Waste reduction in % 1.0 1.0 2.0 Online quality check

Reduced process fluctuations
Cut in material consumption in % 2.0 1.5 3.0
 lighter boards – consistent quality

Speed increase in % 0.5 0.5 6.0 Closest approach to the quality limit

Facility data Cut in cost

1,000 m³
Daily output
Mean raw board dens
Amount of coverage
ity
of cost
650 kg/m³
40 €/m³
2,000* €/day
Cost of wood
Cost of glue
50 €/t
250 €/t 660,000* €/year
50 €/h
Cost of workforce *minus operating costs

+ reliable online quality forecasts

+ cost savings by easy adjustment of the quality level
+ increase in production speed
+ reduction of downtime, rejects and raw material

Boundary conditions for a successful implementation

Prod-IQ.quality uses the measuring and sensor technology
integrated in the plant. As a rule, only few additional inputs
have to be made, e.g. outdoor and hall temperatures as
well as humidity of air. Important parameters like glue
properties or screen analyses that were retrieved manually
can be input manually as well.
The measuring devices of a plant should be serviced and
calibrated at regular intervals. The plant operator is also
responsible for data maintenance including input of the
physical properties and subsequent model updating. This
requires relatively little time – but remember that it is vital
for a successful system operation.
 maintenance 11

Preventive maintenance and repair

Undoubtedly: A systematic and predictive on-condition strategy will maintain the value
of an investment and increase its dependability in the long run. Prod-IQ.maintenance is
an efficient system for supporting maintenance and repair on machines and plants by
systematizing the respective actions.

Logic tree
All maintenance objects are neatly arranged in the logic tree of Prod-IQ.maintenance. It is a
hierarchic structure of factory, plant, groups, assemblies, components and parts. Each maintenance
object may contain ample information: maintenance criteria and intervals, maintenance instructions,
CAD or pictures to support maintenance.
12 maintenance

Process link
There is something very distinctive about the process link of Prod-IQ.maintenance: The required
data are directly read from the control systems integrated in the plant. Maintenance orders may be
carried out cyclically, on-condition, or in a combination of both. The module evaluates precisely the
operating hours, cycles or temperatures and loads and generates the maintenance orders afterwards
in dependence of the as-is condition of the plant. This will help increase the dependability and useful
life of the plant, while at the same time reduce the extent of maintenance.

Benefit of a web based structure

The module is web based which means it can be easily accessed from each computer.
Prod-IQ.maintenance features a simple handling, enabling to save the maintenance
objects, the respective documents and orders in no time.

Repair management and weak-point analysis

Predictive maintenance shall be complemented by a weak-point analysis to identify the causes of repeating
or similar failures. This requires systematic documentation. Prod-IQ.maintenance has an additional
repair management feature including repair requisition, processing status update and feedback after the
order has been executed. The evaluation of the data saved in Prod-IQ.maintenance will reveal any
weak points and exhibit the adequate counteractions to be taken.

+ scheduled, predictive and on-condition maintenance

+ increase of plant dependability
+ maintenance reduced to a minimum
+ efficient weak-point analysis
 options 13

For extensions
Cost trending
This module depicts the actual cost of the current production order. Adjustable cost coefficients
are used to assess any deviation from the set values for speed, material and glue consumption.
The effects of the plant settings on the cost will be visualized and become transparent right away.

Prod-IQ® for the finishing line

Data collection and report creation for the finishing line which may include e.g. a sanding line and a cut-to-size
system including packaging line. The reports contain the evaluation of production orders and days – including
uptime and downtime, total number of board (sanded/cut-to-size, 1st grade and 2nd grade) and rejects. The
data will be integrated into the Prod.IQ.basics standard modules.

+ customization of standardized evaluations

+ collection, representation and control of cost
+ fast and easy product changes
14 options

Order module with ERP interface

The function is to read and list automatically all the production orders from SAP or other
ERP systems. In preparation for a product change the operator selects an order from
Prod-IQ®, transferring the order data to the input system of the plant. There the operator
loads the formulas referred to by the order code for the individual plant sections.
The product change can be initiated in manual or semi-automatic mode. On completion
of a production order the pertaining production and consumption figures will be reported
back to the ERP system using e.g. standardized XML data.

ERP (e.g. SAP)

Customer‘s order


Actual
production data
Production order Art.-no. AB123
Prod: 1,120 m3




Lab interface
At the lab interface the data are exchanged between Prod-IQ® and the customer’s lab system.
This will minimize manual inputs. Prod-IQ® exports the time stamp of a lab sample as well as
the pertaining process data in the form of an XML or a CSV-file, enabling the lab system to read
the data. In turn, Prod-IQ® imports the values measured on a lab sample by reading the XML
or CSV-file created by the lab system.
Notes

Foto Seite 2,15: © Sarunyu_foto – Fotolia.com

Siempelkamp’s process control system

– an intelligent tool which will improve the
profitability of any plant.
 Siempelkamp Maschinen- und Siempelkamp CZ s. r. o. Hombak Maschinen- und Anlagenbau GmbH
Anlagenbau GmbH & Co. KG

Engineering

Siempelkamp Maschinenfabrik GmbH ATR Industrie-Elektronik GmbH Sicoplan N.V.

Siempelkamp Logistics & Service GmbH Büttner Energie- und Ventilatoren – Apparatebau
Trocknungstechnik GmbH

Machines & Handling

Siempelkamp (Wuxi) Machinery Manufacturing CMC S.r.I.
W. Strothmann GmbH
Co. Ltd., China

Sales companies / Representatives

Australia Russia
Siempelkamp Pty Ltd. Siempelkamp Moscow

Brazil Singapore
Siempelkamp do Brasil Ltda. Siempelkamp Pte Ltd.

China Spain
Siempelkamp (Wuxi) Machinery Manufacturing Siempelkamp Barcelona
Ltd., Beijing
Turkey
France Siempelkamp Istanbul
Siempelkamp France Sarl
USA
India Siempelkamp L.P.
Siempelkamp India Pvt. Ltd.

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from Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG. © Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG

Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG Siempelkampstraße 75 47803 Krefeld Germany Tel.: +49 (0) 21 51/92-30 Fax: +49 (0) 21 51/92-56 04 www.siempelkamp.com