Discussing control loop optimization with Control Station's Bob Rice

Key takeaways

Integrating the right technology into existing systems is crucial for maximizing operational efficiency.
Strong collaboration between organizations can lead to significant improvements and the successful implementation of technology.
Deployment plans for technology can be aggressive, but with effective planning and partnership, they can be achieved ahead of schedule.
Control loop performance monitoring needs to be viewed as a cultural initiative, requiring ongoing engagement and accountability.
Documenting successes can motivate teams and drive further improvements across an organization.

Summary

Introduction to Control Loop Optimization

In this episode of Processing Proves, host Daniel Getty speaks with Dr. Bob Rice, Vice President of Engineering at Control Station. They discuss an impactful case study involving Smurf at Westrock, a paper and packaging company that achieved millions in savings through the use of Control Station's Plant ESP software. The conversation dives deep into how this software fits into the company's broader digital transformation strategy, emphasizing the importance of choosing the right tools that integrate with existing systems.

The Aggressive Deployment Plan

The deployment plan at Smurf at Westrock is characterized as aggressive, aiming for implementation across 24 facilities and 25,000 control loops within just 18 months. Bob highlights this as ambitious, citing the scale of work required, including extensive training and logistical planning. It was through close collaboration with Westrock's corporate team and third-party integrators that they managed to surpass their initial timeline, completing the project in under 14 months.

Collaborative Success and Continuous Improvement

Bob emphasizes the unique collaboration between Control Station and Smurf at Westrock, attributing their success to mutual trust and a shared vision for optimization. The partnership extended beyond mere software provision; it involved regular meetings for continuous improvement and adaptation of the software to meet evolving needs. This ongoing engagement ensured that the software was not just a one-time solution but a part of a culture of accountability and performance measurement.

Cultural Integration of Control Loop Performance Monitoring

A pivotal theme discussed is the understanding that control loop performance monitoring transcends software solutions; it's a cultural initiative that requires commitment and accountability. Bob stresses the importance of documenting successes and fostering a culture that seeks continuous improvement. He shares insights on how Westrock documented their savings as motivation for further adoption of the technology across other mills.

Show notes

The company's vice president for engineering talks with managing editor Daniel Gaddy about how PlantESP software helped a paper and packaging company see millions of dollars of improvements.