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LinePlanIndustrial Architecture
SECTOR 04Continuous Process, LGV & Converting

Shop-Floor Management from Pulp Blend and Paper Machine to LGV Autonomous Transfer and Converting Lines

In integrated tissue paper and converting plants, manufacturing begins with recipe-controlled blending of long-fiber, short-fiber and broke pulp bales, followed by winding giant 'Tambour' (Parent/Jumbo) rolls on the paper machine and slitting them on the rewinder. Slit parent reels are transported autonomously by Laser Guided Vehicles (LGVs) to intermediate storage or directly to converting lines (toilet tissue, kitchen towel, napkin, facial tissue), embossed, perforated, packaged and palletized. The field architecture unifies this entire flow.

Covered Shop-Floor Stations: Pulp Preparation & Pulper, Paper Machine (Tambour & Rewinder Slitting), LGV Autonomous Reel Transfer, Converting Lines, Statistical Quality Control (SQC) Laboratory and Finished Goods Warehouse

5 Core Stations

Sequential Shop-Floor Flow

Pulp Recipe → Paper Machine → LGV Transfer → Converting → Pallet & Warehouse

45+ Field Screens

Operator & Supervisor UI

Pulp blend, tambour/reel POD, LGV grouping, converting POD, SQC and Plant Monitor

LGV Integration

Autonomous Intralogistics

Autonomous reel grouping and call-off from paper machine exit to converting lines

SQC, UD & OEE

Quality & Efficiency

Basis weight/caliper/strength SQC tests, Usage Decision (UD) and Henkaten/OEE tracking

01 — 5-STEP SEQUENTIAL SHOP-FLOOR WORKFLOW

Sequential Screens from Raw Material to 3D Warehouse

In this sector, shop-floor operations progress across 5 sequential stages. At each stage, responsibilities are structured across operator cockpits, shift supervision, quality engineering and 3D spatial monitoring.

STEP 01

Pulp Raw Material Preparation, Furnish Blend Recipe and Chemical Dosing

Manages selection of long-fiber, short-fiber and broke bales from inventory, charging into the pulper line according to the pulp blend recipe, and automated wet-end chemical dosing.

Operator Screens (POD)

  • Pulp Combination (Furnish Blending) Operator Screen
  • Long Fiber, Short Fiber and Broke Charge Addition Screens
  • Paper Machine Chemical Automation and Dosing Monitor

Shift Supervisor & Control

  • Pulp Blend and Recipe Compliance Report
  • Order Release and Order Priority/Sequence Management Screen

Quality & Laboratory

  • Pulp and Incoming Raw Material Quality Inspection Screen

3D Digital Twin & Warehouse

  • Plant Inventory and Order Components View (Live pulp and semi-finished stock by storage location, batch and work center)
STEP 02

Paper Machine — Tambour (Parent/Jumbo Roll) Winding and Rewinder Slitting

Controls winding of tissue web into giant 'Tambour' (Parent/Jumbo) rolls at the paper machine reel-up, slitting into customer or converting widths at the rewinder, weighing and individual barcode labeling.

Operator Screens (POD)

  • Paper Machine Operator Panel (POD) and Order Detail Screen
  • Tambour (Jumbo Roll) Creation and Tambour List Screen
  • Slit Parent Reel List and Label Printing Screen

Shift Supervisor & Control

  • Paper Machine OEE, Daily and Monthly Production Efficiency Report
  • Paper Machine Trim Loss / Broke and Yield Report
  • Order Analysis and Order Closure Management Screen

Quality & Laboratory

  • Paper Machine Quality Result Entry and Usage Decision (UD) Screen
  • Statistical Quality Control (SQC), Paper Anomaly and Non-Standard Reel Screen

3D Digital Twin & Warehouse

  • Live Speed and Trend Monitor (Paper machine instantaneous m/min speed, shift average speed and output trend charts)
STEP 03

Reel Grouping and LGV (Laser Guided Vehicle) Autonomous Logistics

Pairs slit parent reels at the paper machine left/right exit stations and dispatches Laser Guided Vehicles (LGVs) for autonomous transport to semi-finished storage or directly to converting line unwind stands.

Operator Screens (POD)

  • Paper Machine Reel Grouping Screen
  • Converting Reel Grouping and LGV Reel Call-Off Screen
  • Semi-Finished Reel Inventory Creation Screen

Shift Supervisor & Control

  • Stock Reclassification and Attribute Change Panel
  • Reel Inventory Movement and Traceability Log Screen

Quality & Laboratory

  • Pre-Transfer Non-Standard / Blocked Reel Interlock Check

3D Digital Twin & Warehouse

  • LGV Autonomous Transfer and Reel Pairing Panel (Live mission and status monitoring of left/right reel stations and LGV fleet)
STEP 04

Converting Lines (Perforation, Embossing, Winding, Log Saw and Packaging)

Tracks parent reel unwinding and consumption on converting lines, monitoring line speeds, speed losses, product group changeovers, Henkaten (change point) logs, downtimes and automated maintenance (PM) requests.

Operator Screens (POD)

  • Converting Operator Panel (POD) and Parent Reel Consumption Screen
  • Downtime Entry, Automated Downtime Splitting and Maintenance Request Screen
  • Shift Operator Checklist and Henkaten Change-Point Screen

Shift Supervisor & Control

  • Converting OEE, Tonnage and Shift Production Reports
  • Top Downtimes, MTBF, Maintenance Stops and Group Changeover Reports
  • Work Plan and Machine Hierarchy Management Screen

Quality & Laboratory

  • Converting Quality Result and Usage Decision (UD) Screen
  • Converting SQC and Non-Standard Product Management Screen

3D Digital Twin & Warehouse

  • Plant Monitoring Cockpit (Live plant board displaying running state, speed, active order and downtime status across all paper machines and converting lines)
STEP 05

Palletizing, Forklift Operations and Finished Goods Warehouse Management

Completes palletizing of cases from converting lines, individual pallet label printing, digital forklift shift checklists and warehouse transfer with inventory reconciliation.

Operator Screens (POD)

  • Pallet Production Confirmation and Label Printing Screen
  • Forklift Operator Pre-Shift Checklist Screen
  • Production Confirmation Reversal Screen

Shift Supervisor & Control

  • Pallet Administration Panel
  • Forklift Inspection and Energy Consumption Report
  • Integration Queue Monitor and System Parameters Panel

Quality & Laboratory

  • Final Pallet Quality Release and Full Track-Record Genealogy Report

3D Digital Twin & Warehouse

  • Warehouse and Inventory Control View (Real-time matching of finished/semi-finished warehouse locations, batch stock and active work center requirements)

02 — INTEGRATION LAYERS

Enterprise ERP and Shop-Floor Automation (Level-2 / PLC) Integration

ENTERPRISE ERP INTEGRATION SCOPE

  • Releasing paper machine and converting production orders to shop-floor screens with priority, sequence and furnish recipe attributes
  • Automated consumption of long fiber, short fiber, broke and wet-end chemicals according to pulp blend ratios
  • Individual barcode/batch inventory receipt and consumption for tambour rolls, slit parent reels and finished converting pallets
  • Usage Decision (UD) processing and non-standard reel/pallet stock governance driven by laboratory SQC results

SHOP-FLOOR AUTOMATION, DEVICE & 3D TELEMETRY SCOPE

  • Paper machine wet-end chemical automation, instantaneous speed (m/min), sheet break/downtime sensors and weigh-scale integration
  • LGV (Laser Guided Vehicle) fleet controller integration for reel grouping, left/right station pairing and autonomous transport missions
  • Converting line PLC speed monitoring, automated speed-loss / downtime splitting and preventive maintenance (PM) notification triggering
  • Industrial reel/pallet label printers, handheld RF terminals and digital forklift pre-shift inspection checklist terminals

03 — CUSTOM SECTOR SOLUTION MODULES

Specialized Shop-Floor Developments in This Sector

MESDEV-04.1

Full Genealogy from Pulp Furnish Blend to Tambour, Parent Reel and Converting Pallet

Continuous material genealogy linking pulp blend ratios to Paper Machine tambour rolls, slit parent reels and finished converting pallets.

OPERATIONAL REQUIREMENT

When a quality deviation occurs on a converting pallet, tracing back to the exact parent reel, tambour roll and pulp fiber blend via paper logs takes days.

ARCHITECTURAL APPROACH

  • Linking long-fiber, short-fiber and broke batches on the Pulp Combination screen directly to the active paper machine order.
  • Generating unique IDs for each tambour roll (Jumbo Roll) and slit parent reel with automated trim-loss and yield calculation.
  • Associating every parent reel consumed at the converting unwind stand with the resulting finished pallets.

OPERATIONAL VALUE

Bidirectional track-and-trace from customer pallet back to pulp bale batch is retrieved within seconds.

MESDEV-04.2

LGV (Laser Guided Vehicle) Reel Grouping and Autonomous Line Feeding Integration

Grouping heavy parent reels at the paper machine exit and dispatching LGVs for hands-free transport to intermediate storage and converting lines.

OPERATIONAL REQUIREMENT

Manual tracking of multi-ton paper reels across converting lines causes wrong-grade reel loading and transport bottlenecks.

ARCHITECTURAL APPROACH

  • Pairing reels at left/right exit stations by quality grade and width on the Paper Machine Reel Grouping screen.
  • Allowing converting operators to call required reel groups from their POD screen, automatically assigning transport missions to the LGV fleet.
  • System interlock blocking LGV transport of non-standard or unapproved (pending UD) reels to converting lines.

OPERATIONAL VALUE

Semi-finished reel traffic between the paper machine and converting lines operates autonomously without grade mix-ups.

DIGITAL TWINDEV-04.3

Plant Monitoring Cockpit, Statistical Quality (SQC) and Group-Changeover OEE Engine

Centralized supervision of live speed, order progress, Henkaten change points, SQC quality and OEE across all paper and converting lines.

OPERATIONAL REQUIREMENT

Frequent product group changeovers on converting lines alter ideal cycle times and distort OEE calculations, while speed losses and quality anomalies go unnoticed during the shift.

ARCHITECTURAL APPROACH

  • Visualizing live speed (m/min), run/stop state and active order progress for all work centers on the Plant Monitoring Cockpit.
  • Dynamic OEE calculation engine that automatically switches target speed and ideal cycle time upon product group / format changeover.
  • Direct integration of laboratory SQC measurements and Usage Decision (UD) screens with production confirmations.

OPERATIONAL VALUE

Speed losses, format changeover durations and SQC quality deviations are captured within the shift for accurate OEE visibility.

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Related Technical Architecture Publications

MES · 6 min read

Pulp Blending, LGV Autonomous Intralogistics and Shop-Floor Execution in Paper & Converting Plants

Managing paper machines, Laser Guided Vehicle (LGV) autonomous reel transport, converting POD screens and Statistical Quality Control (SQC) in tissue and converting plants.