Stora Enso November 2019

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

S

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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ABB Ability™ Collaborative Operations supports a path to this future, offering data-driven decision guidance for a mill’s human operators, a key first step towards more autonomous operations.

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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

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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.”

w w w.sto ra e n s o. com

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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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STORA ENSO

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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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