Paper 360
IMAGE COURTESY OF AICC
Artificial Intelligence can unlock data that corrugated plants can use to optimize product design, anticipate equipment failures, and prevent supply bottlenecks—but there are a few first steps for box makers that want to harness AI’s capabilities.
Over the past few years, one topic has dominated the conversation across all sectors of business: Artificial intelligence (AI). While widespread use of AI tools like ChatGPT have only emerged recently, AI processes have been used in manufacturing settings for decades.
That said, AI capabilities are improving at an exponential rate and are already significantly influencing the corrugated industry. Let’s gain a better understanding of what AI is and how it will be affecting box makers in the future.
WHAT IS AI, AND HOW DOES IT WORK?
AI refers to the simulation of human intelligence in machines that are programmed to think and learn like humans. It is a broad field of computer science and technology that aims to create systems or software that can perform tasks that typically require human intelligence, such as understanding natural language, recognizing patterns, making decisions, and solving complex problems.
The key ingredient for modern AI is data. AI systems require large amounts of data to learn and make decisions. This data can be text, images, videos, sensor readings, or any other type of information relevant to the task at hand. The quality and quantity of data are crucial for AI’s performance.
HISTORY OF AI IN CORRUGATED PRODUCTION
The integration of AI into the corrugated industry reflects the drive toward automation and efficiency that began in earnest in the late 1980s. Initially, AI was employed in corrugated manufacturing primarily for robotics and automation tasks. This early application focused on automating straightforward, repetitive tasks such as part handling and sorting. These automation efforts were aimed at enhancing production rates and operational efficiencies, ensuring that manufacturers could handle large volumes while minimizing human error and labor costs.
As AI technology evolved through the 1990s, it brought more sophisticated algorithms and improved robotics control systems to the corrugated industry. These advancements allowed for greater customization and flexibility in the production machines used in corrugated box manufacturing. AI-enabled systems began not only to oversee the mechanical aspects of production, but also integrated better quality control measures and precision monitoring during production cycles.
THE FUTURE OF AI IN CORRUGATED
The excitement for AI in corrugated today is around the potential of machine learning. Machine learning (ML) is a subset of artificial intelligence that involves training algorithms to recognize patterns and make decisions with minimal human intervention.
“Machine learning enables computers to develop algorithms and make predictions without explicit programming,” said Gokul Gopakumar, vice president of technology and business development at SUN Automation Group. “This is unlike anything we have today. The algorithms are not written out by programmers, they are learned.”
Machine learning offers exciting new capabilities for box plants:
Product Design: AI-powered design tools enable product designers to use vast amounts of data to predict design outcomes, optimize design elements, and personalize products to individual preferences. In real time, ML algorithms assist in generating and improving product design, significantly reducing the time and cost associated with traditional design processes.
Digital Factories: A digital factory is a dynamic, virtual representation of a real-world entity or system, mirroring its physical counterpart in real-time. With a digital factory, an operator can instantly analyze the data from ongoing operations and adjust production settings accordingly. This enables the optimization of operations in real time, without a moment wasted.
“One of our long-term goals of this digital factory is to allow clients from other factories to automatically check our production capacity and schedule their own product manufacturing accordingly, all without needing a person to step in,” said Greg Tucker, CEO and chairman at Bay Cities Packaging and Design. “This kind of automation is becoming increasingly important to stay competitive in this fast-moving industry.”
Predictive Maintenance: Through AI, corrugated manufacturers can anticipate equipment failures before they occur, dramatically reducing downtime and maintenance costs. This is achieved by analyzing vast quantities of data from sensors and historical maintenance records, allowing ML algorithms to identify patterns and anomalies that signal potential issues. By providing actionable insights and precise predictions about when and where maintenance is needed, AI ensures more efficient allocation of resources, prolonging the lifespan of equipment and optimizing operational efficiency.
Additionally, there is the potential for AI to proactively order parts. By deeply understanding machine usage patterns, AI can ensure that necessary parts are always available, enabling immediate replacements and repairs, circumventing supply chain bottlenecks and avoiding overstocking inventory.
Advanced Production Automation: Automation is increasingly being infused with AI, leading to unprecedented levels of efficiency, versatility, and precision (see sidebar). While highly repetitive tasks have long been automated in manufacturing, innovations such as autonomous mobile robots (AMRs) take it to the next level.
Using cameras and laser-based navigation systems to operate around factory personnel and equipment, AMRs give manufacturers a mobile platform and advanced collaborative robotics capable of automating nearly any manual task. The AMRs can be equipped with custom end-of-arm tooling to aid in tasks such as material delivery, screw driving, picking and placing, adhering, sorting, and more. The AMRs can perform similar tasks at multiple locations on a line using just a single robot, maximizing return on investment and minimizing initial automation costs.
HOW TO GET AI-READY
While the most significant advancements in the next generation of AI are still on the horizon, box plants can take critical steps now to best prepare for when these advancements arrive:
Build your data stack: To effectively use artificial intelligence (AI), corrugated manufacturers need to start by organizing and categorizing their data. It’s important to set up a system where all the data from different processes is collected in one central place, often termed a “data lake” or “data warehouse.” Moreover, by employing a data organization protocol, each piece of data can be tagged and categorized systematically.
“Think of this as organizing data with a Dewey Decimal System, categorizing the data in a library digitally,” explained Tucker. “Data is an event, and tagging the event with a protocol that enables instant recall in real time is going to take corrugated far into the world of Industry 4.0 and 5.0.”
Familiarize your team with AI tools: Corrugated plants can begin familiarizing their teams with established AI tools like ChatGPT and Copilot to help team members become more adept at using AI to streamline their daily tasks. In creative departments, tools such as Midjourney and DALL-E can assist designers by generating graphics for backgrounds and settings, allowing artists to focus on the artistic aspects of their projects. Management’s role in advocating for and adopting these tools is crucial for nurturing a culture that is receptive to innovation and ready for the hybrid workforce of tomorrow.
Open conversations with your OEMs: Corrugated manufacturers may face challenges in accessing and using the machine data that is crucial for transitioning into an AI-driven operation. Box plants should proactively engage in conversations with Original Equipment Manufacturers (OEMs) and software providers to negotiate access to this data.
Often, OEMs may be hesitant, concerned about safety, network security, or the protection of their intellectual property. However, by demonstrating robust cyber security measures and clarifying the intent to use the data for operational efficiency rather than competitive purposes, manufacturers can mitigate these concerns.
ARE YOU FUTURE READY?
In the near future, AI integration in paper-based packaging production will become the global industry standard. At SuperCorrExpo® 2024, the Artificial Intelligence on the Production Floor Forum will delve further into the topic, equipping production managers with the knowledge required to best implement AI and gear up for the future. Join us as we explore the strategies and technologies that are pushing the industry forward.
Located at the Orange County Convention Center in Orlando, FL, SuperCorrExpo® will take place September 8-12, 2024. To learn more, please visit supercorrexpo.org.
_____________________________________________________________________________________________________________
Finding Automation
At SuperCorrExpo®, the exhibit will spotlight next-generation AI and robotics solutions from a variety of providers, including:
- Alliance
- Apex
- Assetware
- Bobst
- Emmepi Group
- Kaska Robotics
- N.E. Engineering
- Rigorous
- Sun Automation
- WPR
- WSA-USA
