Procution loss analysis

Everyday there are many disturbances in process units in the mill. Keeping track of when these disturbances started, when they stopped, lost production, lost time, and their causes, is typically a manual job for the operator or shift foreman

MOPS Production Loss Analyzer (PLA) automatically brings the operator continuous information of how his department runs according to target. PLA can calculate Overall Equipment Efficiency (OEE) that provides benchmarking capability for apples-to-apples comparisons.

PLA automatically records values based on predefined rules per department and time period. Exceptions occur when certain conditions are met. For example, when values are outside product dependent limits, or when a paper machine enters a state such as: stop, setup, sheet break, broke or reduced speed. Reason codes and causing objects can be selected for each exception and signed off by the responsible people in the department.

At a glance, operations can see exactly what’s been down, when it happened, how long it was down, what the reason was and what equipment was involved.

Weekly and monthly reports can be created to summarize the production efficiency over the chosen period relative to target production, along with a list of exceptions and the losses caused. A number of reports can be created, e.g. Pareto chart showing the worst reasons.

Additionally, with PLA‘s unique data structure, it can also be used to monitor quality excursions, environmental emissions, and grade run analysis.

Frequently asked questions

We’ve compiled answers to some of the most frequently asked questions about MOPS. If you have additional questions about our systems, projects, or services, don’t hesitate to reach out to us!

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What’s the ROI of MOPS?

Every mill is unique, and the benefits of MOPS can vary. Common areas of return include cost savings in processes and improved data management across mill-wide and enterprise-wide operations. Customers have reported significant improved results as:

  • Yield improvement
  • Chemical savings
  • Reduction in off-grade products

While we can’t promise specific outcomes for your mill, we can guarantee that MOPS provides the tools you need to drive measurable improvements.

What are the benefits of MOPS?

MOPSsys serves as a Manufacturing Information Warehouse for your mill, delivering key advantages such as:

  • Improved customer service
  • Reduced quality losses
  • Increased production
  • Seamless support for corporate ERP systems
  • Greater production flexibility
  • Reduced downtime
  • Enhanced environmental control and reporting
  • Lower raw material, energy, and chemical costs

MOPS provides the tools you need to optimize operations and drive efficiency across your mill.

We already have a Process Database. Why add MOPS?

You don’t need another database if you already have one—that’s great! But what about the applications? MOPS isn’t just a database; it’s a Manufacturing Information Warehouse with specialized tools for:

  • Automating production loss time reporting (PLA)
  • Analyzing paper and bale quality information (PQIS, BQIS)
  • Evaluating and reporting quality production statistics (QPS)
  • Tracking machine equipment performance (MET)

MOPS adds value by delivering actionable insights and streamlining processes beyond what a standard database can offer.

What makes MOPSsys different?

MOPSsys is dedicated exclusively to the pulp, paper and tissue industry, but works in other production or laboratory business also. Our deep understanding of the challenges modern mills face allows us to deliver proven, cost-effective solutions tailored to your needs. Customers value our expertise in implementing systems because we don’t just provide technology—we understand your business. From process databases to specialized mill applications, we offer tools designed to help you improve operations and profitability.

What technology powers MOPS?

MOPS is built for the Windows platform using technologies making access available from other platforms. The MOPS platform is modular, composed of micro-services and micro-frontends, making it possible to customize and extend installations to meet the needs of each customer. The user interface is based on standard web browsers. Communication protocols are HTTP for regular service requests and MQTT (Message Queue Telemetry Transport) for asynchronous event distribution, ensuring access from any system.