Track Mill Yard Operations in Real-Time with Digital Twin Technology

In mill yard operations, maintaining efficient and precise operations is essential for achieving production goals. Every stage of the process, from raw material handling to finished product output, involves complex decision-making based on a constant flow of data. However, most mills still rely on outdated methods for tracking and managing these mill yard operations, often resulting in inefficiencies, increased downtime, and missed opportunities for optimization of production.

This is where digital twin technology is useful. By creating a real-time digital replica of physical assets in mill yard, it offers an unprecedented level of visibility into mill yard operations. YardManager, specifically designed for managing mill yards and warehouses, is a prime example of how this technology can be applied. It enables businesses to track, monitor, and optimize every aspect of their mill yard operations with more precision and foresight.

Digital Twin Technology: A New Approach to Mill Yard Operations

At its core, digital twin technology involves creating a dynamic, virtual model that mirrors the physical environment or operation it represents. In a mill setting, this model can be continuously updated with real-time data collected from sensors, machines, and other IoT devices. These virtual models enable operators and managers to see the current status of equipment, materials, and processes in a way that was previously impossible.

This digital representation is advantageous over traditional methods, which often depend on static reports or manual data tracking. By providing real-time information, digital twins allow businesses to make proactive, data-driven decisions, helping to streamline processes, reduce downtime, and optimize production.

YardManager: Integrating Digital Twin Technology in Mill Yard Management

ConiferSoft’s YardManager is an example of how digital twin technology can be applied to mill yard and warehouse management. Specifically designed for recycled paper mills, YardManager combines real-time tracking of raw materials with a digital model of the mill yard. This system provides visibility into critical operations such as raw material inventory, and quality control, all in one unified platform.

YardManager’s approach to mill yard management is rooted in its ability to provide continuous visibility into the movements and status of raw materials. By incorporating real-time data and integrating it with digital twin technology, YardManager transforms the way production teams manage their resources and workflows.

Real-Time Visibility into Mill Yard Operations

YardManager is equipped with a map-based interface that allows supervisors, production planners, and operators to visualize the entire mill yard and warehouse operations in real time. Through this system, every material, whether it’s a bale of recycled paper or another raw input, is tracked digitally. This constant stream of real-time data ensures that the mill yard is always up to date, providing accurate, current information about inventory levels, material location, and material properties such as grade and quality.

For forklift drivers, YardManager’s vehicle application displays essential information like incoming deliveries, production orders, and bale properties. The application dynamically shows the location of raw materials within the yard, helping drivers navigate efficiently and ensuring that materials are moved according to production orders. This system not only reduces the chance of human error but also improves efficiency in operations by ensuring that the right materials are always in the right place at the right time.

Achieving Consistency and Quality with Predictive Insights

YardManager's use of digital twin technology goes beyond tracking raw materials—it also enables predictive analytics to optimize production quality. By monitoring the feed of raw materials into the production process in real time, YardManager can help predict pulp quality based on the properties of materials being fed into the system. This predictive capability ensures that production teams can achieve a homogeneous mix, minimizing variability and ensuring that the final product meets the required quality standards.

The real-time tracking and predictive quality assessment also play a crucial role in maintaining consistency throughout the production cycle. With accurate and up-to-date information, operators can make informed adjustments to material feeds and production schedules to address any deviations or issues as they arise, reducing the risk of production delays and quality issues.

Data-Driven Decision Making and Reporting

YardManager’s real-time dashboards and reporting features enable managers to make data-driven decisions with ease. Through detailed reports on material consumption, production orders, machine work, and storage balance, managers can quickly assess the performance of their operations and identify areas for improvement. For example, reports on inventory levels and deliveries help track the availability of raw materials and allow operators to anticipate shortages or overstocking issues before they affect production.

These reports are generated automatically based on real-time data, eliminating the need for manual bookkeeping or outdated spreadsheets. This not only saves time but also ensures that data is accurate and up to date. Furthermore, YardManager’s integration with other mill systems—such as the mill gate system, ERP, and production systems—makes it easier to compile and share comprehensive reports across departments, streamlining internal communication and decision-making processes.

Improving Sustainability through Data-Driven Practices

Digital twin technology is not only about improving operational efficiency, it also provides an opportunity for mills to embrace more sustainable practices. By tracking every aspect of the raw material process in real time, businesses can optimize material usage, reduce waste, and improve energy efficiency. This level of optimization helps mills operate more sustainably, contributing to reduced environmental impact and better resource management.

YardManager for Modern Mill Yard Management

The integration of digital twin technology into mill operations, as demonstrated through YardManager, represents a significant step forward for the forestry and recycling industries. By providing real-time visibility, predictive insights, and data-driven decision-making tools, YardManager enables mill operators to optimize their operations, improve production quality, get savings, and reduce downtime. Additionally, the system’s ability to automate reporting and simplify compliance tracking makes it an invaluable tool for modern mill yard management.