Connected AI from ei³ drives strong improvements on the converting plant floor

The Challenge

The packaging manufacturer needed to enhance value for their customers by addressing several interconnected manufacturing challenges. Their goal was to develop a comprehensive system that would minimize machine downtime and address operator concerns while providing a reliable framework for improved operations.

• Monitoring operational data from individual machines to plant-wide systems and presenting it meaningfully

• Establishing uniform metrics across diverse equipment from various manufacturers and time periods

• Facilitating data-driven decisions for both management and factory floor personnel

• Optimizing machine recipes and enhancing quality control

• Identifying improvement opportunities while establishing fail-safes against previously undetectable problems

The Solution

The manufacturer's introduction to ei³ began with a laminator installation from a leading printing and converting machine builder that incorporates ei³'s secure IoT apps into all new equipment. Recognizing the significant advantage these capabilities offered in an industry with narrow profit margins, the company extended ei3's Connected AI solution beyond the initial laminator to older equipment including slitters, bag machines, and printing presses.

The implementation features continuous 24/7 monitoring of machine data using ei³'s Amphion edge device, creating secure connections to diverse equipment. All collected data is centralized within ei³'s private cloud, where KPIs are computed and Connected AI's AI-based tools generate insights. These insights are accessible through various devices, from smartphones to HMI dashboards, supporting operators, quality control personnel, and management alike.

Early detection in action: ConnectedAI identified a Laminator bearing failure before downtime occurred

Dashboard providing a three-month analysis of Splitter Machine downtime, using codes assigned by plant personnel

By integrating ei³'s suite of no-code IoT and AI apps—Monitor, Downtime, Recipe, and Quality—across over 70 machines, the company established a robust foundation for data-driven decision-making and continuous improvement.

Results

• Maximized Machine Productivity: Utilized controller data to identify prominent causes of downtime and employed analytics tools for continuous improvement projects. The system detected vibrations in a laminator before bearing failure, preventing production quality issues and unplanned downtime.

• Operational Efficiency Boost: Efficiently managed machines across diverse lines and locations with comprehensive insights on machine speed, material usage, OEE breakdown, and downtime. This significantly reduced overall downtime, enhancing operational efficiency.

• Streamlined Machine Configuration: Enabled supervisors and operators to set ideal parameters based on previous data and experience, creating a library of "good" settings for efficient adaptation of new machines to changing client demands.

• Consistent High-Quality Deliverables: Facilitates real-time testing on various machines. Enables operators and QA techs to create testing sequences with customizable variables. Ensures consistent high-quality deliverables in the competitive packaging industry.

About the Manufacturer

A prominent North American packaging company began their journey into AI-powered, data-driven manufacturing by incorporating ei³ technology into a single laminator. Today, the company has expanded to connect 70 machines across five locations to ei³'s solution, fully embracing data-driven machine operations. Beyond mere metrics, the company experiences reduced downtime, improved quality control, and elevated customer satisfaction and loyalty.