The future of manufacturing just got smarter at Stora Enso
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Stora Enso: the future of manufacturing just got smarter WRITTEN BY
DAN BRIGHTMORE PRODUCED BY
MANUEL NAVARRO
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STORA ENSO
Stora Enso’s digitisation programme is realising the benefits of automation and 5G to optimise efficiency, flexibility, and availability in production
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tora Enso is among the world’s oldest companies with more than 700 years of heritage, encompassing mining, iron and
wood activities, stretching back to the 13th century. Today it focuses on all of the possibilities to manu04
facture a diverse range of products made from renewable materials with the forest and the trees as their foundation. Marko Yli-Pietilä, Head of Smart Operations at Stora Enso, is in charge of driving the digitalisation and transformation programmes allied to global smart operations in all areas of the business: consumer board, bio materials, paper, packaging solutions and wood products. “The Smart Operations team is responsible for accelerating digitalisation in our operations, but that is only one part of Stora Enso’s overall digitalisation programme. We also look at digitalising the customer interface, supply chain digitalisation and back office digitalisation with HR and finance processes,” he says. “In addition to this, we work with the startup community to develop new digital solutions as well
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as nurturing our own internal startup initiatives to develop new digital products.” One of those successful solutions is the new retail solution for unmanned retail, which was launched during 2019. The digitisation of Stora Enso’s manufacturing fleet comprises around 100 production lines across many factories and is vital to achieve higher operational efficiency. “Operationally, we manufacture a diverse range of wood-based products. We’re also producing many w w w.sto ra e n s o. com
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that can inhibit peak performance. This improves return on capital. In particular, ABB’s solutions are helping to: • Centralize and streamline operations. By applying remote connectivity and analytics to process and equipment data, producers can empower teams in centralized control rooms, which have the automated tools and visualization capabilities to help teams make decisions and process improvements, throughout the mill and also the enterprise. • Increase energy efficiency. Technologies that enable the alignment of production schedules to energy supply and demand help optimize energy usage according to fluctuating energy costs. • Achieve safety goals. Using technologies that increasingly automate tasks within the space of rotating and moving machinery reduces the risk of injuries. Meanwhile, remote services and augmented reality can help avoid human contact with live current. • Reduce costs through advanced process control (APC). Delivering APC using a performance-based approach and business model allows mills to stay ahead of problems and continuously optimize processes to make more with less. This also allows mills to focus improvements on known areas of complexity like the pulp mill and the wet end of the paper machine. The future, today Whatever the specifics of an operation or solution, ABB is supporting and guiding the pulp and paper industry on its journey toward ever more effective use of digitalization, creating next-level operations and realizing significant cost benefits. With its forward-thinking approach and industry-leading solutions, such as ABB Ability™ Collaborative Operations and ABB Ability™ Advanced Process Control, ABB is ready to be your partner in shaping the future, today.
STORA ENSO
completely new products, such as fiber- based composites,” says Yli-
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“ The Smart Operations team is responsible for accelerating digitalisation in our operations, but that is only one part of Stora Enso’s overall digitalisation programme. We also look at digitalising the customer interface, supply chain digitalisation and back office digitalisation with HR and finance processes” — Marko Yli-Pietilä, Head of Smart Operations, Stora Enso
Pietilä. “My role is focused on smart operations, which means the digitisation of production and maintenance needed to keep our factories running efficiently also in future.” Stora Enso started investing in its digitisation programme three years ago and has now completed around 160 different projects including artificial intelligence (AI), augmented reality, machine learning (ML) and virtual reality (VR). “We’ve tested almost all of
CLICK TO WATCH : ‘DRONE WOOD YARD INVENTORY’ 09 the technologies on the Gartner hype
Whatever you need to do in your work
curve,” reveals Yli-Pietilä. “We’re using
here, you can do while on the move.”
big data and examining different kinds
Yli-Pietilä believes people are a hugely
of wearables, including smart glasses.”
important aspect of this transforma-
He adds that analytics is probably the
tion. “They need to learn new skills to
strongest area of focus at present. “We
understand how analytics works and
have company-wide mobile maintenance
be familiar with different mobile tools,
tools available both for maintenance
because there will be many applications
personnel and operators when they do
used in the field, and also in different
maintenance-related tasks. Our peo-
operating rooms. It’s very important
ple can also do safety notifications on
we create a unified user experience to
the move, and we also visualise things
teach users,” he says of the company’s
already in 3D formats. The use of 3D
quest to develop unified UIs.
models makes it’s very easy to under-
To support these transformation
stand where things are happening.
goals the company has created a Stora w w w.sto ra e n s o. com
OUR INDUSTRIAL INTERNET OFFERING Advanced reporting and guidance
Asset reliability optimization
Operations performance optimization
Valmet Performance Center
A meaningful dialogue with data Accumulation of high-quality data will be a key source of future business value. While machines and equipment are one part of a wider, intelligent production system that creates value, software and analytics will play an increasing role in transforming data into digital services and solutions. At Valmet, the offering of Industrial Internet applications and services is based on know-how in process technology, automation and services. This unique combination gives industry specific, proven solutions.
Ultimately, data analytics is just one of many methods available to support decision making. Other methods must also be brought into play to enable the analysis of variations and the comparison of different options.
Improved predictability, profitability and quality
From system-level control to a holistic process approach
Advanced analytics provide good tools to evaluate indicators signaling a need for predictive maintenance, such as temperature and vibration measurements or energy consumption. A good example of the capabilities of advanced analytics is paper machine web break prediction, where root causes for breaks are analyzed and a prediction model is developed. This enables monitoring the parameters affecting a web break and issuing early warnings so that corrective action can be taken before the break happens. Another example is paper strength modelling, which allows controlling of raw material parameters so that a specified paper strength is achieved while optimizing the raw material usage from a cost point of view.
Thanks to the accumulating data, it is possible to take a holistic approach and optimize production by evaluating the entire production chain. Industrial internet also enhances asset management and brings value by making both processes and operations more effective. → www.valmet.com
STORA ENSO
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Enso design concept called SEEDS
an environment capable of fostering
(Stora Enso Design System). “SEEDS
a collaborative ecosystem. “We aim
is a publicly available set of instructions
to build data assets, like the Stora Enso
and code which enables designers and
IIOT platform, which our partners can
developers to build a user experience
access. In that way we can use the
aligned with Stora Enso requirements,”
same data in the applications they
explains Yli-Pietilä. “The companies we
co-develop with us and deliver to us,”
partner with in the digitalisation area
explains Yli-Pietilä.
can access these assets to help them
Three years on and the success of
develop the services they are deliver-
Stora Enso’s approach is already
ing to us.”
apparent with the company achieving
Stora Enso works with a variety of
second place for ‘Best implementation
partners, from agile startups to larger
of IIoT on the shop floor’ at the 2019
companies, with a focus on creating
Industry of Things World Award. “We
are the first company in our industry
Stora Enso’s efforts to achieve key
to have implemented 5G to enable
targets such as “optimising efficiency,
real-time 360° camera solutions in
flexibility, and availability” in production.
our production environment,” says
During the acceleration of its digital
Yli-Pietilä. “This allows experts all over
transformation, Yli-Pietilä reflects on
the world to monitor certain areas
the biggest challenge he and his team
of the production and give guidance
have had to overcome over the past
when needed – ultimately making our
few years. “Handling the massive
production environment more efficient
amount of data we generate in the
and safer.” The 5G solution will support
process industry is always a challenge,”
E XE CU T I VE PRO FI LE
Marko Yli-Pietilä I spent more than a decade at Nokia, in a variety of telecommunications roles and then worked in data management, and data warehousing,” recalls Stora Enso’s Head of Smart Operations, Marko Yli-Pietilä. “This experience was perfect preparation for my role at Stora Enso.” Communication and data will be the cornerstone for the 5G revolution, one that Yli-Pietilä is excited to welcome in with the wealth of opportunities it will provide for efficiency and productivity. “My background helps to understand what you can actually do with the data and how you need to organise the data in order to have it in use in the best possible way. And with my experience in management consulting, I appreciate the value in combining digital assets or data assets, how you use the data across distances, and how you then transform this data into something valuable.” He believes organisations can utilise the new capabilities offered by digital transformation to achieve many business targets including revenue growth, better operational efficiency and improved customer experience management.”
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STORA ENSO
700+
Years of history
€10.49bn Approximate revenue
26,000 14
Number of employees
15
w w w.sto ra e n s o. com
sustain peak performance.
Benchmark your actual process and asset performance data against your expected performance with Honeywell Forge for Industrial, for better decisions that impact reliability, safety and profitability. For more information, please visit: www.honeywellprocess.com/iiot
he admits. “We’re constantly looking at how we can get the data to be available for these advanced intelligent applications and is why we decided to build a Stora Enso IIoT (Industrial Internet of Things) cloud-based platform. We are using a lot of resources to organise the data in the cloud so that we can have this integrated data asset in use by these applications that we are building in collaboration with different vendors.” When Stora Enso needs to communicate across operations in real-time this is achieved by the close proximity of its digital tools to the production
“ SEEDS is a publicly available set of instructions and code which enables designers and developers to build a user experience aligned with Stora Enso requirements” — Marko Yli-Pietilä, Head of Smart Operations, Stora Enso
line. Now, Yli-Pietilä is keen to take things a step further. “We want to predict what will happen in the future, and
reliability. “We want to be able to
we also want to prescribe. We’re trying
advise people to take actions to make
to do prescriptive analytics, not just to
the future look like we want it to look,
tell users what will happen in the future,
with product quality, machine perfor-
but also advise them what they need to
mance, and the reliability of equipment
do to perform in their work in the best
related to the maintenance,” confirms
possible way. We’re building prescrip-
Yli-Pietilä.
tive analytics solutions using AI and
“How we measure the success and
ML, because then you’re not actually
performance of these tools is actually
in real-time — you’re in the future.”
through the business KPIs that we use
Stora Enso already has AI-based
to measure our operational efficiency
applications in use that can see
in general. We start following up those
12 hours into the future with good
business KPIs, so that our digital w w w.sto ra e n s o. com
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STORA ENSO
SU S TA I N A B I L I T Y AT STO R A EN SO
Stora Enso supports all 17 of the United Nations Sustainable Development Goals (SDGs); the following three goals have been identified as the most strategic to the business: SDG 12: The use of renewable materials. Involvement in the bioeconomy and circular economy. Innovating to improve resource and material efficiency.
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SDG 13: Renewable materials are an important part of the carbon cycle. They grow back and keep absorbing carbon dioxide and storing carbon. Identify and analyse carbon risks and opportunities to establish their financial and non-financial impacts, the likelihood of their occurrence, and their root causes. Stora Enso is the first to set ambitious science-based targets for reducing its greenhouse gas emissions in 2017. SDG 15: 100% of Stora Enso’s main raw material, wood, comes from sustainably managed forests that grow back. Safeguarding forest biodiversity. As wood is its most important raw material, Stora Enso’s key risks cover forest and land use.
transformation becomes a normal part of our business development also linked to profit and operations improvement.” Yli-Pietilä explains how prescriptive tools can help maintain ongoing production quality. “Paper is produced at around 100km per hour and you need to be able to adjust the process in real-time to maintain the quality our customers expect. Those tools require calculation and predictive capabilities for us to be able to advise the operators that are running the machine to do the process changes necessary to keep production at the optimal level for as long as possible.” The company is also considering testing more flexible and intelligent robots, such as exoskeletons, to assist production workers. Elsewhere, testing is underway to examine the potential benefits of audio analytics. “Based on the sounds we are hearing, we’re analysing how machines are running and if there’s any evidence of a potential malfunction in the future,” he explains. Across its business development the two most important trends for Stora Enso are climate change and sustainability. “After all, we are in the w w w.sto ra e n s o. com
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business of replacing fossil-based
“ We’re building prescriptive analytics solutions using AI and ML, because then you’re not actually in real-time – you’re in the future” — Marko Yli-Pietilä, Head of Smart Operations, Stora Enso
material with materials that are made out of wood,” says Yli-Pietilä. “We have been transforming our product portfolio for years towards that goal.” Though in smart operations Yli-Pietilä’s team have focused on the operational efficiencies of the manufacturing fleet, their efforts are still contributing to sustainability targets with energy efficiency for example. “We are very keen to develop our water treatment processes to be more sustainable every day and CO2 is something we
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are looking at really carefully and how
and availability of the machinery
we can bring those numbers down to
because by increasing the automation
contribute positively to our climate
level we can then affect these key KPIs
change targets,” he confirms.
positively. While we’re doing this, it
With automation levels in its mills
automatically makes the workplace
already high, Stora Enso aims to raise
safer every day.” With automation on
automation levels further while making
the rise, Yli-Pietilä believes the concept
work safer. “If we can automate more of
of ‘dark mills’ is firmly on the agenda
the potentially dangerous operations,
for helping to build a sustainable future.
we will also be increasing our overall
Digitisation has unlocked the door;
operational efficiencies (OEE),” adds
Stora Enso is taking steps to shape the
Yli-Pietilä. “OEE is our most important
corridor beyond.
KPI when it comes to operations. We will then look at performance, quality, w w w.sto ra e n s o. com
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