Helios Uses Data Science To Take Guesswork Out Of Corrugator Uptime The corrugated facility is a delicate ecosystem, made up of hundreds of thousands of moving parts. The ripple effect of a jam or snag, or one worn-out tread on a conveyor can be instant and it can be massive: an unforeseen breakdown. But on the other end of the spectrum, the impact can be slight enough to go unnoticed to machine operators and technicians, but still significant enough to decrease out- put, margins, and, over time, the bottom line. Both of these scenarios are undesirable for the same reason--even the most seasoned operators could be completely blindsided by these situations. A machine breakdown means hours or even days of lost output, but a subtle slowdown could be costing the company a comparable amount of money if it goes unremedied for too long. For nearly 150 years, since the genesis of corrugated manufacturing, keeping machines online has been an in- exact science, bordering on pure superstition. But this has all changed thanks to advancements in data science and machine learning. Now, it is possible to turn every part of every machine in a corrugated facility into a source of ac- tionable intelligence. Anomalies Predict The Future To most corrugated machine operators, jams, slow- downs, and breakdowns are the beginning of the story. Too often the approach is reactionary, waiting until something goes wrong to spring into action. This may mean freeing up a jam, ordering a new part, or clearing out a buildup of debris. But in the technologically equipped corrugated fa- cility, these problems can be avoided, because the subtle signs that forecast an impending issue will notify operators and plant managers before the problem occurs. This is all possible by digitally mining anomaly data. Data mining is the process of looking for patterns in the nonstop deluge of data constantly generated by a facility. Most corrugated machines are currently generating data, such as output numbers, changeover speed, frequency of jams, and many other things. However, most of this data goes un-analyzed because it is simply too constant, too voluminous, and in many cases, too subtle. But when run through a data analysis platform, such as the brand-ag- nostic corrugated data platform Helios, this seemingly meaningless, infinite, infinitesimal information is a gold- mine. These algorithms are specifically designed to detect anomalies. An anomaly is any behavior, impact, or output that deviates from the norm or breaks from expectations. Helios flags anything unusual, such as a slight variation in rate, a noise or vibration that is abnormal, a misfire, an error, a jam, or any of a nearly endless list of other things that could go wrong. Even the slightest variation could be an indication of an impending serious issue, and it can alert operators, or even off-site regional supervisors of a potential problem on the horizon. CONTINUED ON PAGE 34
Board Converting NEWS INTERNET DIRECTORY
THE HAIRE GROUP www.hairegroup.com
Haire Group is the premier provider of new machinery for the corrugated industry. As the exclusive US & Canadian agent for one of the largest machinery manufacturers in the world, Haire Group is able to pair clients with the best machinery solutions for the best value to meet their spe- cific needs. As an operating partner of the US-based DFA Technical Support Center (a joint venture of Haire Group and Dong Fang), Haire Group delivers top-notch 24/7 pro- fessional, reliable service and support, maximizing quality and uptime. Additionally, Haire Group has been the indus- try’s #1 pre-owned machinery broker and plant equipment appraiser since 1976. HarperLove is the leading provider of specialty adhesives, performance additives, and wet-strength resins to corru- gated packaging manufacturers. With the largest and most experienced field service and technical support team posi- tioned throughout the U.S. and Latin America, HarperLove has a long-standing reputation for providing outstanding service and delivering demonstrable performance improve- ments. HarperLove’s renowned services include not only innovative product development and custom product for- mulation, but also machine and process assessments, ad- hesive formula adjustments, machine tuning, detailed ser- vice reporting, and more. HARPERLOVE www.HarperLove.com
KIWIPLAN www.kiwiplan.com
Kiwiplan - premier worldwide software provider of enter- prise-wide, fully automatic solutions specifically for the cor- rugating and packaging industries. Kiwiplan’s Total Solution delivers comprehensive, seamless real-time flow of infor- mation from sales order management to dynamic total plant scheduling and inventory control through shipping.
MAROTECH INC. www.marotech.com
Manufacturer of Marotape®, Marotape®Plus, Marotape® FPT and MaroString™; hot melt coated tapes and strings used for reinforcement and easy-open features for pack- aging. Marotech Inc. also manufactures state-of-the-art dispensing and tape placement equipments to optimize the productivity of applying hot melt coated tapes in pack- aging.
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May 3, 2021
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