Forintek, Tembec, Comact and McMaster University have developed the Smart Mill Assistant (SMA), a real-time system that rapidly detects when the process is out of control. The SMA will assist sawmill managers and supervisors with detecting, identifying and correcting process deviations.
The SMA relies on the acquisition and analysis of process data in real time. Multivariate statistical analysis, simple data analysis and visualization methods have served as a basis for the development of monitoring and diagnostic models. The SMA monitors the process at two levels. The first model monitors the overall process. It can detect when the process is out of control, and identify the variable or machine centre responsible for a problem, but it does not, however, identify the factors responsible for the problem. At the second level, we have developed an expert system for one machine centre, the bull edger, which is capable of detecting problems, identifying the causes for them, and suggesting solutions to mill users.
The SMA has been implemented in a Tembec pilot sawmill. Based on the models in place, we estimate that gains of $5 to $10/Mbf are theoretically achievable. Actual gains will vary with the type of equipment, personnel reaction time and its ability to correct problems. At the time of report preparation, the evaluation of actual gains was not totally completed.