How “Converting 4.0” could radically reshape the way ...ready for Industry 4.0 ~ Converting 4.0,...
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2017 Quarter 4 • www.convertingquarterly.com 43 continued on page 44 u CONVERTING OPERATIONS Introduction I s the term “Converting 4.0” just a flashy catchphrase? Or is it a convergence of trends and technologies that promises to reshape the way materials are processed in the world of converting? Talk about Converting 4.0 to a company president, director of operations or a production manager of a converting business, and you might get a blank look in return. If they have heard of it, they are likely to be confused about what it is. If they haven’t heard of it, they’re likely skeptical of what they see as yet another piece of marketing blather, a.k.a. “an empty catchphrase.” Yet a closer look at the future developments of Converting 4.0 reveals some powerful emerging technologies with a strong potential to change the way a converting plant operates. It may be too much to say, as some might, that this “Industry 4.0 ~ Converting 4.0” is another industrial revolution. But, call it whatever you like, the fact is Converting 4.0 is a gathering force, and management should carefully monitor the coming changes and develop strategies to take advantage of these new opportunities. Understanding the terms Let’s start with some definitions. We can define Converting 4.0 as the next tool for productivity growth that is driving machine and process development of the converting industry. This justification of Converting 4.0 is driven by the following trends: 1) The astonishing rise in the volume of low-cost data collection. 2) The steady decrease in cost for increased computing power. 3) The connectivity of the machines through new low-power, wide-area networks. 4) The emergence of analytics and business – intelligence capabilities and improvements in transferring digital instructions to the physical world of converting machinery. These four trends are the future reasons for allowing Converting 4.0 to be used economically. Converting 4.0 could be thought of as the next major step in the evolution of modern converting process. This follows the lean revolution of the 1970s, the introduction of gearless presses, solventless lamination and the cantilevered, rewind shafts of slitter/rewinders during the 1980s. This trend continued with the computer phenomenon of the 1990s How “Converting 4.0” could radically reshape the way materials are processed By Randy Wolf, dir.-business development, Kampf Machinery Corp. USA and the automation that took off in the early 2000s. The next logical step in the world of converting is the development and introduction of Converting 4.0. Most of these digital technologies and data-collection processes have been growing for some time now. Some are not yet ready for application at scale, but many are now at a point where their reliability and lower cost are starting to make sense for applications in the converting industry. However, a lot of companies in the converting industry are not consistently aware of or prepared for these emerging technologies. In a recent survey, only 25% of converters consider themselves ready for Industry 4.0 ~ Converting 4.0, and only a similar share of machinery suppliers actually consider themselves in a position to offer it in some shape or form. Data, data and more big data So, let’s assume that we are prepared to enter into Converting 4.0, in which operators, computers and automation will all come together in an entirely new way, with slitter/rewinders, laminators and printing presses all connected remotely to computer systems equipped with machine algorithms that can learn and control the machine production with input from human operators and computers. Converting 4.0 introduces what can be called the “Smart Data Factory,” in which cyber-physical systems monitor the entire converting process and make real-time decisions through real- time data collection. The physical systems become the Internet “ Is Converting 4.0 just a flashy catchphrase, or a convergence of trends and technologies that promises to reshape the way materials are processed? ”
Transcript of How “Converting 4.0” could radically reshape the way ...ready for Industry 4.0 ~ Converting 4.0,...
2017 Quarter 4 • www.convertingquarterly.com 43continued on page 44 u
CONVERTING OPERATIONS
Introduction
Is the term “Converting 4.0” just a flashy catchphrase? Or is it a convergence of trends and technologies that promises
to reshape the way materials are processed in the world of converting?
Talk about Converting 4.0 to a company president, director of operations or a production manager of a converting business, and you might get a blank look in return. If they have heard of it, they are likely to be confused about what it is. If they haven’t heard of it, they’re likely skeptical of what they see as yet another piece of marketing blather, a.k.a. “an empty catchphrase.” Yet a closer look at the future developments of Converting 4.0 reveals some powerful emerging technologies with a strong potential to change the way a converting plant operates. It may be too much to say, as some might, that this “Industry 4.0 ~ Converting 4.0” is another industrial revolution. But, call it whatever you like, the fact is Converting 4.0 is a gathering force, and management should carefully monitor the coming changes and develop strategies to take advantage of these new opportunities.
Understanding the termsLet’s start with some definitions. We can define Converting 4.0 as the next tool for productivity growth that is driving machine and process development of the converting industry. This justification of Converting 4.0 is driven by the following trends: 1) The astonishing rise in the volume of low-cost data
collection.2) The steady decrease in cost for increased computing power. 3) The connectivity of the machines through new low-power,
wide-area networks.4) The emergence of analytics and business – intelligence
capabilities and improvements in transferring digital instructions to the physical world of converting machinery.
These four trends are the future reasons for allowing Converting 4.0 to be used economically. Converting 4.0 could be thought of as the next major step in the evolution of modern converting process. This follows the lean revolution of the 1970s, the introduction of gearless presses, solventless lamination and the cantilevered, rewind shafts of slitter/rewinders during the 1980s. This trend continued with the computer phenomenon of the 1990s
How “Converting 4.0” could radically reshape the way materials are processedBy Randy Wolf, dir.-business development, Kampf Machinery Corp. USA
and the automation that took off in the early 2000s. The next logical step in the world of converting is the development and introduction of Converting 4.0.
Most of these digital technologies and data-collection processes have been growing for some time now. Some are not yet ready for application at scale, but many are now at a point where their reliability and lower cost are starting to make sense for applications in the converting industry. However, a lot of companies in the converting industry are not consistently aware of or prepared for these emerging technologies.
In a recent survey, only 25% of converters consider themselves ready for Industry 4.0 ~ Converting 4.0, and only a similar share of machinery suppliers actually consider themselves in a position to offer it in some shape or form.
Data, data and more big dataSo, let’s assume that we are prepared to enter into Converting 4.0, in which operators, computers and automation will all come together in an entirely new way, with slitter/rewinders, laminators and printing presses all connected remotely to computer systems equipped with machine algorithms that can learn and control the machine production with input from human operators and computers.
Converting 4.0 introduces what can be called the “Smart Data Factory,” in which cyber-physical systems monitor the entire converting process and make real-time decisions through real-time data collection. The physical systems become the Internet
“Is Converting 4.0 just a flashy catchphrase, or a convergence of trends and technologies that promises to reshape the way materials are processed?”
44 www.convertingquarterly.com • 2017 Quarter 4
t continued from page 43
CONVERTING OPERATIONS
of Things (IoT), communicating and cooperating both with each other and with the machines and humans in real-time via the wireless Web or through the Cloud.
For a factory or system to be considered Industry 4.0 ~ Converting 4.0, it must include the following:• Inter-operating machinery
– machines, sensors and people that connect and communicate and share data with one another.
• Information transparency – the systems create a virtual copy of the physical world through sensor-data collection to manage information.
• Technical assistance – both the ability of the systems to support humans in making decisions and solving problems, and the ability to assist humans.
• Decentralized decision-making – the ability of cyber-physical systems on machines to make simple decisions on their own and become as autonomous as possible.
But, as with any major shift, there are challenges inherent in adopting Industry 4.0 ~ Converting 4.0 models:• Data security issues are
greatly increased by integrating new systems and more access to those systems. Additionally, proprietary production knowledge becomes an IT security problem as well.
• A high degree of reliability and stability are needed for successful cyber-physical communication that can be difficult to achieve and maintain in some plant environments.
• Maintaining the integrity of the production process with less human oversight could become a barrier.
• Loss of high-paying human jobs is always a concern when new automation and technologies are introduced.
• Avoiding technical problems that could cause expensive production outages is always a concern.
Additionally, there is currently a systemic lack of experience and manpower to create and implement these systems, not to mention a general reluctance from management and shareholders to invest heavily in these new, young technologies.
But, the benefits of Industry 4.0 ~ Converting 4.0 models could outweigh the concerns for many converting facilities. In some challenging working environments, the health and safety of human operators could be improved dramatically. Supply chains could be more readily controlled when there is real-time data at every level of the converting process. This data collection would produce much more reliable and consistent productivity and
FIGURES 1-2. Converting 4.0, a.k.a. Smart Data Factory, uses cyber-physical systems to monitor the entire converting process and makes real-time decisions through real-time data collection.
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output with less waste. The results for many converters could be increased revenues, market share and real profits.
ConclusionThe question then is not if Industry 4.0 ~ Converting 4.0 is coming to our world of converting, but how quickly? As with all new business trends, early adopters of this new movement will face some challenges. However, in the long-term, these pioneers will be rewarded for their courage for jumping into this new integrative platform.
Machine suppliers that are forward-thinking and have invested in research and development will be offering Converting 4.0. They will advance these new integrative platforms for the benefit of their customers in our ever-changing world of converting. n
Randy Wolf, dir.-business development at Kampf Machinery Corp. USA (Windsor, CT), holds a Bachelor’s degree in Sales & Marketing from William Paterson University (New Jersey). He has 40+ years of experience in the converting industry, thus gaining a continuing education from the engineering side. Wolf is a member of the LinkedIn groups Slitting Community and Flexible Packaging Professionals, and the Flexographic Technical Assn. He can be reached at 770-781-5291 email: [email protected], www.kampfusa.com.
Converting 4.0We are . . .
+ Communicate
+ Integrate
+ Inform
+ Create Knowledge
= Increase Efficiency
Kampf Machinery Corporation | www.converting40.com | [email protected] | www.kampfusa.com
