The TestGrid displays reel and roll-level test results in a webpage that is used by wet end operators, machine superintendents, and mill managers to see consolidated quality anywhere in the mill when the reel is accepted in the lab. Columns of (PantherStats) test and profile statistics are immediately posted. Colored results show warnings and specification limit excursions. Drill-down functionality allows the user to witness test trends and make a paper machine adjustment before bad paper is produced. PantherStats data ensures quality results are actual and accurate across the entire reel and not relying on filtered, masked machine control statistics.
You can also drill-down to display individual tests. For example, click on the Basis Weight test on the test screen to drill down and view the actual Basis Weight profile.
This also applies for all lab tests. If lab tests were trending towards a warning or failure limit, the graph provides ample warning before producing bad paper.
Data is captured automatically and inserted into the TestCentral open relational database in date/time stamp order, and with roll/set and reel number associations.
PantherStats is an exclusive and embedded algorithm delivered with TestCentral. PantherStats uses raw profiles and lab tests to calculate actual reel and roll statistics based on industry defined standards regardless of the source of the originating data. Since machine control profile statistics are filtered, composited and smoothed for control purposes, they cannot provide accurate, actual “as cut” roll statistics that build reliable production results for shipped rolls.
PantherStats resolves these fundamental statistical errors, and TestCentral recalculates the actual statistics against the finished as-cut winder roll. This re-calculation also overcomes quality error problems whenever winder pattern changes are made between planned and actual production patterns.
TC Online provides a means to view lab test quality information over the web. It includes access to products tests and limits, machine runtime history, reel summaries with drill down, and reports by authorized users. It also connects to the database to gain direct access to orders that provides planned and produced roll information.
By consolidating quality with production information via a common web access portal, the user saves valuable time retrieving information for reports and customer service. TC Online was designed by paper mill users who needed to find information quickly and easily without searching through large amounts of generic information. To use the full power of TestCentral Online, it requires installation of the MillTools® MES applications or an interface to other systems for the data.
Machine downtime events can be recorded in TestCentral via a user-friendly entry grid. This information is available from the ReportsWeb.
Both current reel and look-ahead testing options are supported. This allows different mill testing processes to be incorporated, including last reel or next reel quality result assignment.
Paperless profile average recording
With TestCentral, all the scanning profiles (each data box) and associated data are saved electronically, eliminating the related costs for printers and paper storage. PantherStats is applied uniformly to both machine profile and lab test data.
Test values from the TestGrid and the reports can be exported to other software packages, such as Microsoft Excel.
The Base System includes the database and three common set up utility applications: Product Target, User Manager, and Mill Configuration, plus the TestGrid, PantherStats and TC Online features.
Lab Test Console
Lab Test Console is the main lab application where turn-ups are processed and saved to the database. Test configuration and set up is also managed in this application. Lab Test Console is a required component of the TestCentral system.
It includes a set of tabs that are used for system set up and configuration, turn-up notification, lab test gathering, machine downtime event recording, reports page access, user message log and help files.
Input Node is a lab operator application for entering and accepting test results. The application can run on either touch screen or standard desktop PC’s. Typically, a lab has several workstations running Input Node positioned close to the bench test instrument. The design saves time for the operator running multiple tests on a sample from the completed reel.
A standard web-based Certificate of Analysis (COA) report provides a report on roll quality. Customized COA Reports are also available based on unique mill or customer requirements. Panther offers a service to build the COA, per customer requirements, to include the required data and desirable layout for produced rolls when they are shipped on a Panther manifest.
ReportsWeb is the Panther report selection tool which enables a user to define the scope of a report using filters. For example, the user selects the machine ID, production date, and downtime category to view the standard Downtime Summary report automatically. ReportsWeb can be used by any authorized mill or corporate user.
Web-enabled displays provide instantaneous access to TestCentral data from any remote company Intranet browser. This provides a means to investigate and resolve production quality inquiries quickly and efficiently.
On-screen and (resultant) hard copy reports provide PantherStats driven reel, roll and set summaries, as well as all product tests. Also, the user may choose to display other process information. The standard displayed and hard copy reports include:
- Reel Summary
- Grade Summary
- Lab Quality Summary
- Grade Quality
- Down Time Summary
- Down Time Detail
- Product Test Limits
- Reel Average
- Roll Average
- Test Profile
Interfaces to external devices and systems are a necessary part of successful lab systems. It is important to collect data from various sources, including physical testers, paper machine system profile scanners, process information systems, MES systems and business systems. All these various sources play a role in the ability of TestCentral to provide a comprehensive accounting of finished roll quality results. Furthermore, accurate and uniform results can only be achieved via the unique underlying PantherStats technology.
Test Device Interface — Discrete
For bench instrument single-variable testing
TestCentral has a repertoire of over 30 interfaces that collect test data automatically from a bench top instrument. The operator inserts the paper test strip and pushes a button on the test device to begin testing. The test is taken and the data is available to the operator in the Input Node application. This includes single and/or multiple test samples.
Test Device Interface — Automatic
For automatic multi-testers
TestCentral includes an interface to common automatic testing systems. When the auto-tester is run, the system automatically captures the test results.
OPC 2.0 client
The OSI (PI) SDK Client is used to interface to the OSI PI system to exchange data and profile information when this is the preferred user system for data extraction. This requires the user to have a copy of the OSIsoft PI DAP server SDK interface for operation.
Base System & Other Support
TestCentral is supported by a set of common database and other software modules to provide a complete integrated approach for paper mill production management. The base system and other support applications include:
- Database: an open SQL database developed and supported by Panther
- Front Office: Orders to Invoicing
- Warehouse/transportation management: inventory to shipping
- Communication and interfaces: common modules for reporting and system interfaces
- Software utilities: common modules for system setup of grades, products, user rights, function activation and reports
- Test Lab: ProcessAnalyzer for complete lab quality information and analysis and TesCentral hardware
- PantherQCS: Paper machine measurement and quality control system
Panther Systems supplies complete turnkey services from conception through start up, plus continuing long-term support for installed systems.
Services include project management, gap analysis, hardware architecture, configuration, database population, training (at customer site, Panther headquarters or remotely through the web), and installation.
Continuing Services include Panther HelpDesk management, automatic upgrades, site visits, remote training and high-speed service connection.