Revolutionary digital plant model by Sonae Arauco debuts in Germany

 Tuesday, June 18, 2024

As we stand at the brink of Industry 5.0, the synergy between humans and advanced technologies like artificial intelligence, robotics, the Internet of Things (IoT), digital twins, and virtual reality is revolutionising work processes, pushing them toward greater efficiency and sustainability. Sonae Arauco, a leading name in engineered wood solutions, is embracing this transformative vision by systematically modernising its operations. Recently, they have turned their Nettgau facility in Germany into a fully digitalised plant. This transformation equips the plant with a comprehensive real-time data system, significantly enhancing decision-making and operational efficiency.

According to Dirk Beyer, the Plant Manager of Nettgau: “After a few months of use, we can already validate the main benefits of this model. The digital plant makes it possible to work with accurate information in real-time. Thanks to this easy access to data at any time and the correlation of the different process variables, our specialists can now focus on their areas of expertise, on planning and on solving problems.”

And he adds: “We’re talking about a reduction in bureaucracy, since there’s no longer any need to enter data or calculate Pareto ratios manually, a more accurate daily analysis, with the data being used in practically every meeting, and a shorter response time, which translates into faster and more effective problem solving.”

Everything on one platform-
At the heart of the digital plant, over 2,000 process variables provide an in-depth analysis of key performance indicators (KPIs), from the overarching global metrics down to the most specific details. These are visualised through Pareto diagrams, offering a comprehensive drill-down approach. This vast array of data is accessible to decision-makers at any moment through a unified platform, available from the control room right down to the mobile phone.

This platform, known as the Digital Plant Viewer, is enhanced by a feature called “Smart Notifications.” Leveraging the capabilities of artificial intelligence, it interprets the data and generates alerts when performance deviates from the optimal parameters. When such deviations occur, the system not only sends notifications to the mobile phones of all responsible personnel but also automatically triggers a predefined series of responses. These actions, depending on the severity of the issue, can range from making minor adjustments to halting the production line.

Hand in hand with artificial intelligence-

The implementation of the digital factory brings numerous advantages to Sonae Arauco. It enhances the ability to pinpoint organisational improvements, bolsters the reliability and longevity of the systems, and minimises downtimes. This digital transformation also optimises operational costs and simplifies processes, thereby reducing bureaucracy and freeing up valuable time.

In the past, data collection was a manual and time-consuming task. However, with the advent of digitalisation, business information is now centralised and readily accessible on an online platform. This shift not only streamlines operations but also enables a more efficient and responsive approach to managing the factory’s activities.

Angel Garcia Bombin, Industrial Digital Transformation Director, whose team is responsible for developing the concept of the digital plant and implementing it at Sonae Arauco’s various sites, explains: “The digital factory is changing the way we work. We can receive information in real time and react immediately to unforeseen events. State-of-the-art technologies and human intelligence are closely interwoven and thus offer the greatest possible benefit. This puts us on the direct path to the age of Industry 5.0.”

Advancing with the Digital Plant: A Milestone in Sonae Arauco’s Evolution
The digital plant represents a significant milestone in Sonae Arauco’s journey of innovation, complementing other crucial initiatives, particularly in the realm of predictive maintenance. Presently, the majority of Sonae Arauco’s factories across various countries are equipped with sensors that continuously monitor key parameters such as vibrations, temperature, and amperage.

These sensors feed data into an artificial intelligence system, which analyses the information to determine the optimal timing for maintenance. It also issues alerts when it detects any anomalies. This ongoing data monitoring, coupled with the empowered autonomy of all personnel involved, ensures that responses to potential issues are markedly quicker. Consequently, error durations are substantially reduced, leading to enhanced operational efficiency and reliability.

Read more news on Sonae Arauco

Get more updates on American woodworking industry through: www.woodandpanel.us

Tags: digitalised plant, German woodworking industry, Industry 5.0, Nettgau facility, Sonae Arauco, woodworking industry, woodworking magazine, woodworking news, woodworking UK