Skip to main content

Daily Operations at Blueprint Paper Mill

This scenario walks through a typical morning shift at Blueprint Paper Mill, showing how operators use Cyzag Blueprint for routine daily rounds and asset monitoring.

Scenario: Morning Shift Startup (June 15, 2025)​

Time: 6:00 AM Operator: John Smith (Pulping & Utility Operator) Shift: Morning (6:00 AM – 2:00 PM)

John arrives for the morning shift and needs to verify that all critical equipment in Units A (Pulping) and D (Utilities) is operating normally after the night shift.

Step 1: Review Assigned Rounds (6:00 AM)​

John opens Cyzag Blueprint on his tablet and sees his assigned rounds for the day:

📋 Morning Shift - June 15, 2025

Assigned Rounds:
┌─────────────────────────────────────────┐
│ Morning Shift - Pulping & Utilities    │
│ Status: Not Started                     │
│ Estimated duration: 45 minutes          │
│ Last completed: Yesterday, 6:15 AM      │
│ 6 route stops in Units A and D          │
└─────────────────────────────────────────┘

[Start Round]

He taps "Start Round" and heads to Unit A in the basement.

Step 2: Route Stop 1 – Digester D-101 (6:05 AM)​

John descends to the basement where Digester D-101 is located. Cellular signal is poor here, but the app works normally because it's offline-first.

Reading the Gauges​

John checks the digester control panel and enters readings into Cyzag Blueprint:

  • Cooking Temperature: 168 °C ✅ (normal: 165–172 °C)
  • Digester Pressure: 5.5 bar ✅ (normal: 5.2–5.8 bar)
  • H-Factor: 1150 ✅ (normal: 1100–1200)
  • White Liquor Flow: 42 L/min ✅ (normal: 38–45 L/min)
  • Chip Level: 78% ✅ (normal: 70–85%)
  • Unusual noise or odor?: No ✅

Result​

All readings are within normal range. The app shows green checkmarks for each value and displays:

✅ Digester D-101 - All readings normal

Data saved locally (offline mode)
Will sync when connectivity returns

John taps "Save & Continue" and moves to the next route stop.

Step 3: Route Stop 2 – Feed Pump P-404 (6:15 AM)​

John walks to the pump room (still in basement, still offline).

Reading the Pump Instruments​

  • Discharge Pressure: 12.5 bar ✅ (normal: 11–13 bar)
  • Motor Amperage: 48 A ✅ (normal: 45–52 A)
  • Bearing Vibration: 7.2 mm/s ⚠️ (alert threshold: >6.0 mm/s)
  • Seal Temperature: 42 °C ✅ (normal: <50 °C)

Handling Abnormal Reading​

When John enters 7.2 mm/s for bearing vibration, the app:

  1. Highlights the field in yellow ⚠️
  2. Shows: "Above normal threshold (>6.0 mm/s)"
  3. Prompts: "Please describe the condition"

John adds notes:

Bearing vibration higher than normal. Audible knocking
sound from drive end bearing. Pump still operating but
needs attention.

He taps the camera icon and captures a photo of the pump bearing.

Auto-Generated Observation​

The app creates an observation automatically:

Observation #127
Asset: Feed Pump P-404
Condition: High Bearing Vibration
Severity: Medium
Operator: John Smith
Time: 6:15 AM

Bearing vibration 7.2 mm/s (above 6.0 threshold).
Audible knocking from drive end bearing.
Photo attached.

Status: Flagged for supervisor review

John saves and continues to the next route stop.

Step 4: Route Stop 3 – Black Liquor Tank BL-02 (6:23 AM)​

John returns to ground level where cellular signal is good. As he walks up the stairs, the app automatically syncs all data captured offline (Digester D-101 and Feed Pump P-404 readings).

At the Black Liquor Tank:

  • Tank Level: 65% ✅ (normal: 40–80%)
  • Liquor Temperature: 82 °C ✅ (normal: 75–85 °C)

All normal. Data syncs to server immediately (online mode).

Step 5: Unit D – Utilities Route Stops (6:25 AM – 6:40 AM)​

John moves to Unit D (Utilities) and completes three more route stops:

Steam Boiler B-01 (Boiler House, 6:28 AM)​

  • Steam Pressure: 42.3 bar ✅
  • Flue Gas Temperature: 405 °C ✅
  • Feedwater Conductivity: 3.2 µS/cm ✅
  • Drum Level: 51% ✅
  • Flame Pattern Normal?: Yes ✅

Air Compressor AC-12 (Compressor Room, 6:35 AM)​

  • Discharge Pressure: 7.0 bar ✅
  • Discharge Temperature: 92 °C ✅
  • Motor Amperage: 35 A ✅
  • Oil Level: OK ✅

Cooling Tower CT-03 (Outside, 6:40 AM)​

  • Fan Vibration: 2.8 mm/s ✅
  • Water Temperature: 28 °C ✅
  • Fan Noise Level: Normal ✅

All readings normal in Unit D.

Step 6: Complete Round (6:42 AM)​

After completing all 6 route stops, the app shows:

✅ Round Complete!

Morning Shift - Pulping & Utilities
Started: 6:00 AM
Completed: 6:42 AM
Duration: 42 minutes

Route stops completed: 6 of 6

⚠️ 1 observation flagged for review
   Feed Pump P-404: High bearing vibration

Summary notes for shift handover:
┌──────────────────────────────────────┐
│ All equipment in Unit A and Unit D  │
│ operating normally except P-404      │
│ bearing vibration. Recommend         │
│ maintenance check on day shift.      │
└──────────────────────────────────────┘

[Complete Round]

John adds his handover notes and digitally signs to complete the round.

Supervisor View (6:45 AM)​

Meanwhile, supervisor Maria Lopez sees John's completed round in her dashboard:

📊 Morning Rounds Dashboard

✅ Morning Shift - Pulping & Utilities
   Completed by: John Smith at 6:42 AM
   Duration: 42 minutes
   All route stops: 6 of 6 complete

⚠️ 1 New Observation Requiring Review

Observation #127 - Feed Pump P-404
High Bearing Vibration (7.2 mm/s)
Flagged: 6:15 AM
Operator: John Smith
Photo available

Maria clicks on the observation to review details and takes action:

  1. Views the photo: Confirms visible wear on bearing housing
  2. Reviews trend: Vibration was 4.2 mm/s yesterday, 5.8 mm/s two days ago – trending upward
  3. Adds comment: "Scheduled bearing replacement for day shift maintenance window. Monitor vibration every 2 hours until repair."
  4. Changes severity: Medium → High (due to upward trend)
  5. Updates status: Open → In Review

She creates a work order in the maintenance system referencing Observation #127.

Outcome​

By 7:00 AM:

  • ✅ All critical equipment inspected and documented
  • ✅ 30 readings captured across 6 assets
  • ✅ 1 abnormal condition identified early (Feed Pump P-404 vibration)
  • ✅ Supervisor notified and action taken (maintenance scheduled)
  • ✅ Complete digital record for shift handover and trending

This example demonstrates:

  • Offline operation: 2 of 6 route stops completed without connectivity
  • Automatic flagging: Abnormal reading triggered observation without supervisor involvement
  • Real-time visibility: Supervisor saw completed round within minutes
  • Trending analysis: Historical data revealed worsening vibration trend
  • Proactive maintenance: Issue addressed before equipment failure

Comparison: Before vs. After Cyzag Blueprint​

Before (Paper-Based Rounds)​

6:00 AM – 6:45 AM: John walks the plant with clipboard

  • Records readings on paper form
  • Notices high vibration but writes brief note
  • No photo capability
  • Paper form sits on desk until supervisor reviews it

8:30 AM: Supervisor reviews paper form

  • Can't read some handwriting
  • No historical context (has to look up old paper forms)
  • No photo of bearing condition
  • Calls John to clarify what he saw

10:00 AM: Maintenance finally scheduled

  • 4 hours after issue detected
  • Meanwhile, vibration has worsened
  • Bearing may fail before repair

After (Digital Rounds with Cyzag Blueprint)​

6:00 AM – 6:42 AM: John completes round on tablet

  • Structured readings, impossible to misread
  • Abnormal reading flagged automatically
  • Photo captured immediately
  • Data syncs as soon as connectivity available

6:45 AM: Supervisor sees completed round

  • Observation flagged with photo and notes
  • Historical trend graph shows worsening vibration
  • All context available for immediate decision

7:00 AM: Maintenance scheduled

  • Action taken within 15 minutes of detection
  • Bearing replaced before failure
  • No production downtime

Time saved: 3 hours 15 minutes Production impact: Avoided unplanned downtime Data quality: 100% legible, complete, and traceable

Next Steps​

Explore related scenarios:

Or try the hands-on tutorial: