by Cassandra Balentine
Continued advancement and adoption of digital print in the corrugate printing market has providers reconsidering the efficiencies of their legacy workflows. Among the most essential workflow software is MIS/ERP and MES.
Jack J. Lafler, VP, sales and technical services, HiFlow Solutions, explains that an MIS/ERP provides umbrella software that allows corrugated converters control over every single aspect of their production and business landscape, starting from receiving the RFQ until the final product delivery.
“It inserts automation into every process and streamlines all the tasks related to a job. And it adds visibility in real time to critical KPIs through dashboards that any authorized user has access to,” comments Lafler.
The MES contained among some ERP/MIS gathers data across the corrugated environment and moves it to analytics modules that provide management with real-time shop floor data. “In these ways, corrugated converters utilize the ERP/MIS and MES to optimize their operations,” adds Lafler.
For some, he says MES and MIS/ERP offer the same features and functionality whether the process is digital, flexographic, or offset.
However, Aleks Zlatic, VP, product portfolio and market development, eProductivity Software (ePS), believes that as digital becomes a more viable option for printing to corrugate, it is prompting manufacturers to re-evaluate and enhance their use of ERP and MES software to accommodate the short-run requirements and opportunities presented by digital printing technology.
“This includes tighter integration with digital printing equipment, dynamic job scheduling, enhanced data analytics and reporting, streamlined workflow integration, and increased agility and flexibility in production operations,” shares Zlatic.
Corrugated Considerations
Manufacturers look for ways to reduce labor hours. “Jobs need to get through production in the quickest, most efficient way possible. They need logical ways to maintain strict quality control and produce a high-quality product,” stresses Lafler.
Automation features that streamline manufacturing processes and provide real-time visibility into plant floor and customer data are essential for increasing productivity and reducing errors, shares Zlatic.
Solutions must access this data in a user-friendly, efficient way. “The ability to access business information quickly is key to running a successful company. Decisions need to be made faster than ever, and the right choices can lead to rapid growth of a company,” notes Randy Baer, e-commerce project manager, Durst Group AG.
Zlatic points out that efficient inventory management tracks every aspect of the process—from ordering to consumption—to minimize waste, reduce over-ordering of stock, and maintain optimal inventory levels to streamline production processes and reduce costs.
Precise cost tracking that provides granularity in cost analysis, which is crucial for informed decision making in a competitive market is also an important feature, according to Zlatic.
Manufacturers want metrics on everything that is going on every minute in their operations so they can implement continuous improvement. “They want control over processes—and costs,” agrees Lafler.
“Scheduling optimization to route jobs through the plant in the most cost efficient and optimal way ensures that the customer receives goods promptly,” says Zlatic.
Flexibility in solutions that allow seamless integration into existing ERP systems and workflows is also essential. “Customers want solutions that can be easily adapted to their needs and integrated with other critical business systems, enabling a gradual and sustainable digital transformation,” continues Zlatic.
These environments want solutions tailored specifically for the corrugated industry. “This includes features that address the unique challenges and requirements of corrugated board manufacturers and box converters,” adds Zlatic.
Differing Goals
While workflow tools may handle both analog and digital print technologies, it is essential to consider the end goal of the manufacturer.
“Digital print goals often differ from analog print goals due to the distinct advantages and capabilities offered by digital printing technology. As customers transition to digital printing, they typically need to watch margins much closer due to the smaller/segmented quantities. As a result, they need distinct features and capabilities in MES and ERP software,” says Zlatic.
Whether digital or analog, “many manufacturers are moving towards Industry 4.0, which includes connectivity, visibility, and automation,” shares Lafler.
Capabilities such as personalization, short-run flexibility, quick turnaround times, cost-effective prototyping, variable print quality, substrate versatility, and environmental sustainability are essential requirements. “These demands reflect digital printing technology’s unique advantages and opportunities in today’s competitive and dynamic market landscape,” explains Zlatic.
“What we have seen is that runs are becoming shorter and shorter, and digital helps facilitate those needs as it has the flexibility to make even one-offs a money-making opportunity, but you need to understand your costs and availability,” says Baer.
Lafler points out that digital printing has advantages over other methods of printing folding carton and corrugated such as offset and flexography. “Digital printing now offers both speed and quality. Faster turnaround and the ability to do short-run jobs are a driving force behind digital print.”
Digital printers also offer personalization in a cost-effective way for short runs. “Increasingly, versioning and variable data is required by brands and digital can handle that,” says Lafler.
Shortened pre-production time is a big factor in favor of digital printing. “This is because unlike traditional printing methods that require setup and preparation, digital printing eliminates the need for plates, labor, and machine setup, which is costly for small runs, reducing the time to complete the job. This is why digital is chosen over analog 90 percent of the time,” comments Lafler.
Customers want speed, but they also demand the highest quality. “The quality of digital print is now very comparable to analog so there is less hesitancy to take the digital path over analog methods. Digital printing offers superb color accuracy and sharp details even on corrugated substrates,” says Lafler.
AI and the Future
Discussions of workflow evolution today are not complete without the mention of artificial intelligence (AI).
“AI is going to play huge role in all aspects of our lives, and MES is no different. The more we can utilize this technology to better estimate resource availability, the better a company can quote and plan their production,” admits Baer.
Zlatic points out that AI can be used to revolutionize ERP and MES by enabling predictive analytics, optimized production planning and scheduling, intelligent resource allocation, quality control, predictive maintenance, supply chain optimization, and continuous improvement.
“AI-powered predictive analytics can anticipate future trends, demand patterns, and production issues by analyzing historical data from ERP and MES. This enables proactive decision making, such as optimizing inventory levels, predicting equipment failures, and mitigating production bottlenecks before they occur. AI algorithms can optimize production planning and scheduling in MES by considering various factors such as order priorities, machine capabilities, material availability, and workforce constraints,” explains Zlatic.
AI-driven scheduling algorithms can dynamically adjust production schedules in real time to maximize efficiency, minimize setup times, and meet deadlines.
Algorithms also intelligently allocate resources, including machines, materials, and labor, based on real-time demand and production conditions. “By analyzing ERP and MES data, AI algorithms can optimize resource utilization, reduce waste, and improve production efficiency,” comments Zlatic.
Quality control and predictive maintenance tools benefit from AI-powered image recognition. Further, machine learning algorithms enhance quality control processes by automatically detecting defects and anomalies in manufactured products. “AI can enable predictive maintenance in MES by analyzing equipment sensor data to forecast potential failures and schedule maintenance activities proactively, minimizing downtime and optimizing equipment lifespan,” adds Zlatic.
“AI in manufacturing production boosts every area from production scheduling to tracking production status and quality control. It can be used to detect printing defects and then provide automatic corrections or enhancement,” stresses Lafler.
Supply chain operations are optimized by AI when analyzing vast amounts of data from ERP systems, MES, and external sources such as weather forecasts, market trends, and geopolitical events. “AI algorithms can optimize inventory levels, streamline logistics, and identify cost savings and risk mitigation opportunities across the supply chain,” says Zlatic.
AI-powered solutions enable continuous improvement and adaptive learning. “AI-powered ERP and MES can facilitate continuous improvement initiatives by analyzing production data, identifying inefficiencies, and recommending process optimizations. Over time, these systems can adapt and learn from past performance to continuously refine production processes and drive operational excellence,” he concludes.
Delivering on Demands
The right MIS/ERP allows for a myriad of benefits to manufacturing environments. As more manufacturers consider adding digital printing capabilities for corrugate work it may be time to reevaluate workflows to ensure productivity and efficiency.
Apr2024, DPS Magazine
