Representative ImplementationPaper Manufacturing · Pulp to Dispatch

Transforming Paper Manufacturing with Real-Time Production Monitoring, OEE, and Predictive Analytics

A paper manufacturing facility modernised production operations by replacing manual data collection with a connected manufacturing platform — integrating production machines, quality systems, maintenance workflows, and ERP into one continuously updated view.

How to read this page: this is a Representative Implementation — a composite example based on common implementation patterns and engineering experience, illustrating a typical deployment architecture, workflow, and set of expected operational outcomes. It does not describe a specific named customer. The two headline outcomes below — waste and quality improvement — are the exception: they are verified, previously published results (also cited on SG2's homepage), called out explicitly because they differ from the rest of the illustrative content on this page.

Executive Summary

The facility sought to modernise production operations by replacing manual data collection with a connected manufacturing platform. The project integrated production machines, quality systems, maintenance workflows, and ERP to deliver real-time visibility into machine performance, production efficiency, and quality metrics — enabling plant management to monitor production continuously, identify downtime causes, improve Overall Equipment Effectiveness (OEE), and establish a foundation for predictive maintenance.

Industry

Paper Manufacturing

Production Environment

Pulp Preparation · Paper Machine (PM) · Rewinder · Slitter · Packaging · Warehouse

Business Challenges

Manual production reporting on paper logbooks
Delayed shift reports reaching plant management
No live machine utilisation data
Frequent unplanned downtime with no root-cause trail
Difficult, time-consuming root cause analysis
Limited production traceability from pulp to dispatch
Quality information stored separately from production data
ERP not synchronised with actual production events

Existing Workflow — Before

Delayed reporting, human error, duplicate entries, and no real-time dashboards.

Production Order Operator Starts Machine Manual Log Book Quality Inspection Production Sheet Supervisor Report Excel Consolidation ERP Update

Solution Architecture

PLC Industrial Gateway MQTT / OPC UA Manufacturing Platform Production Database Analytics Engine ERP Power BI Dashboards

Functional Modules

Production Monitoring

  • • Machine status & speed
  • • Production count
  • • Reel information & grade
  • • GSM tracking
  • • Shift production totals

OEE Dashboard

  • • Availability
  • • Performance
  • • Quality
  • • Real-time calculation, not month-end

Downtime Management

  • • Mechanical failure
  • • Electrical issue
  • • Roll change
  • • Material shortage
  • • Quality adjustment
  • • Scheduled maintenance

Quality Integration

  • • Moisture, GSM, thickness
  • • Burst & tensile strength
  • • Lab inspection results

Maintenance

  • • Preventive maintenance schedule
  • • Breakdown records
  • • MTTR / MTBF tracking
  • • Spare consumption

ERP Integration

  • • Production orders
  • • Batch completion
  • • Finished goods & inventory
  • • Consumption & warehouse updates

Dashboards

Plant Dashboard

  • • Current production
  • • Today's output
  • • Running machines
  • • Downtime
  • • OEE
  • • Shift comparison

Machine Dashboard

  • • Machine speed & production rate
  • • Paper grade & current reel
  • • Operator on shift
  • • Alarm status

Quality Dashboard

  • • Rejected rolls
  • • Quality trends
  • • Lab results
  • • SPC charts

Production Traceability

Raw Material Pulp Batch Machine Operator Paper Reel Slitting Packing Dispatch

Business Outcomes

40%

Waste reduction

Verified — published deployment result

25%

Quality improvement

Verified — chemical & speed-control optimisation

Additional outcomes this class of deployment typically targets:

Near real-time production visibility for plant management
Faster identification of downtime causes
Improved production planning accuracy
Reduced manual reporting effort for supervisors
Better product traceability from pulp to dispatch
Improved maintenance planning from structured breakdown data

Technologies

OPC UAMQTTPLC IntegrationREST APIsERP IntegrationReal-Time DashboardsAI AnalyticsPower BIMobile Applications

Future Roadmap

Predictive maintenanceAI quality predictionEnergy optimisationDigital twinAI production scheduling
See the full Manufacturing & Industry 4.0 practice

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