Free Tool Guide To Help Your Packaging Factory Reach Its Highest Potential

Digital transformation, Industry 4.0, operational efficiency, production metrics, manufacturing dashboards and packaging manufacturing are topics that have been following PackIOT for a while now. Throughout all this time we have been trying to show you how technology can play a huge part in our lives and in our manufacturing businesses, specifically. It felt right to do a compilation of the main materials we have created so far that can help you on this journey to become more digital and efficient within the packaging manufacturing world. Below you will find  list of the main free resources that PackIOT has created throughout the past months: 1_Free Guide: 15 Essential KPIs and Metrics For Packaging Manufacturers Plant managers and executives often feel the information overload about the production of their factories. This is a challenge as it becomes more difficult to analyze everything and decide which metrics should be used in their businesses to create better reports and analysis. These manufacturing metrics and KPIs will help you monitor, analyze and, consequently, optimize the production processes in your factory. This will obviously contribute to the improvement of the quality and quantity of produced goods. Our free guide covers everything from production…

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MES or Production Analytics: What Is The Best Solution for My Packaging Factory?

By Mariana Costa, Marketing Specialist at PackIOT Production Analytics is not the same as Manufacturing Execution System - MES. Both are different tools with different goals. We want to help you understand and spot the main differences between these two distinct systems and hopefully help you make better decisions for your factory in the future. The goal of any manufacturing analytics application is always to increase capacity, productivity and throughput. Basically, what all this means is doing more with the same already existing resources. This is achieved by using machine and operator data through which is possible to find and eliminate bottlenecks in the manufacturing processes. In this sense, MES software might present some limitations. While it is possible to identify common functionalities between production (or manufacturing) analytics and MES they are completely different tools used for different jobs. 1_MES - Manufacturing Execution System MES is an information system that leads the execution of manufacturing operations. The goal is always to achieve and maintain high performance. To meet these goals MES is able to perform and complete a group of tasks on the factory floor that are integrated with other systems across the organization: Monitor and enforce…

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My Packaging Plant Already Collects Data. And Now What? Which Questions Should Be Answered?

By Fernando Pacheco, COO at PackIOT The situation described in the title is more common than one can imagine. And if you have come this far, it is likely that you have been facing this challenge in your factory. This problem can occur in several ways (they are not mutually excluding): Your machines are already factory-sensed and deliver general data, but you don't know what to do with it. Your data is stored in the PLC, but nobody could access it in an easy way and/or does not gets insights and information from there (you don't have a front-end tool, in the end). Your plant spends a giant amount of time manually collecting data, but it does not make any decisions. you already have a powerful MES in place, which helps you on a piece of the data journey, but you can't cross these numbers with real production information (actionable data). And after that, of course, these challenges can lead to other difficult situations, usually described by plant managers as below: "I wanted to automate everything. I have the data in different places, but every time we need to put it together, a person needs to sit down,…

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The 4 Advantages of Adopting SaaS vs On Premises for the Packaging Industry

By Mario Ishikawa, CTO at PackIOT The IoT revolution is here and we cannot deny it. What is incredible for manufacturing is that with the IoT adoption on the shop floor, we saw the convergence of OT - Operational Technology with IT - Information Technology, creating the Industrial Internet of Things, or IIoT. It does not mean killing what is already out there, but bringing more connectivity and use cases for so much data that can be collected on a plant. But certainly, there is an overlap. If in the past the stack PLC + SCADA or dedicated gateway was basically the only option to collect data from the process, now there are many more possibilities. And when we are not talking about critical missions, it is certainly viable to think in a system on the cloud. One thing is when you need your operator to keep the process in control using an HMI. Another thing is when you want your manager to study past data to make better maintenance decisions for a packaging line. For that case, a cloud solution, presented as a SaaS (software as a service) offering can have several advantages: 1_Converting CapEx to…

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Women In Manufacturing: Changing The Industry’s Mindset

The jobs in manufacturing are mainly held by men: according to a study by Pew Research Center, in the US women make 40% of the labour force and only 29% work in an industrial field. There are thousands of job places that cannot be filled and it's difficult for manufacturers to hire people for those spots. Women could play an important role in that. This gap needs to be filled, and could actually be filled by females. So how can we convince women to opt for a job position in manufacturing? There is a big number of qualified women in the workforce, so we have to understand careers in the industrial sector, are not that appealing for them. According to a study by Deloitte, women who work in manufacturing feel underrepresented. It is certain that if manufacturers want to have more women working for them, they will certainly need to change their strategy related to recruiting, retaining, and advancing women’s jobs in manufacturing. Nowadays, 6 out of 10 positions are not filled due to a manufacturing skill gap.     WHAT DOES NEED TO CHANGE? 1_DIVERSITY Diversity and profitability are directly correlated. Having teams with a lot…

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PackIOT Talks: Digital Transformation In Action with José Mauricio Coelho, CEO of C-Pack

Digital transformation is a topic that has been following us for quite a while. Since February/March 2020, we all saw how technology plays an important role in our lives, when we were saw ourselves forced to be in quarantine for two or more months straight. Suddenly our home became our office as well and seeing friends and family was only possible through a screen. Technology was our lifesaver during that period as it allowed us to keep in touch with each other. Companies who had not digitalized themselves until then, were forced to do so, in order to survive. “I know this is a hard moment but it is also an important one, where all the technological resources are more required than ever before, not only in the industry 4.0. I think now we are talking about family 4.0, work 4.0. Everybody is migrating to 4.0”. - José Mauricio Coelho, CEO of C-Pack José Mauricio Coelho, CEO of C-Pack Creative Packaging SA, has been following the evolution of technology over the years. He has been managing the implementation process of digital transformation projects. On this talk, he approaches the several obstacles he has come across with and…

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Innovation: Not As Fancy And Complicated As It Sounds

Written by Pedro Kirk, Project Specialist at PackIOT   Most companies are seeking innovation and new ways to present their products and services. That is an undeniable fact. However, there are huge misconceptions around innovation, like what is it, how to achieve it and finally the biggest and the worst of all: “it doesn’t suit my company”. The definition of innovation might be confusing and abstract, probably if you ask 10 different people about it, you will hear 10 different answers. This article does not intend to define it, that is a subject for another post. The idea that matters and is important to keep in mind is: innovation is a continuous process, a way to rethink standards and allow changes to happen.    Innovative vs. Inventive To be innovative does not (always) mean to be inventive! Disruptive concepts and products are the highest level of this process, it does take a while to achieve it. Until then, there is still a lot of value in the journey. Car sharing services, like Uber, or Tesla’s electrical vehicles, among several other examples, have been changing our lives and are considered references to innovation. But does that mean they…

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How An Analytics System Can Help You Reshape The Culture Of Your Manufacturing Team

Written by Leonor Rocha | Customer Success at PackIOT   Every organization has its own definition of culture. Even though we live in a globalized world, there will always be specific characteristics connected to the local and national culture that will define an organization. Culture can be regarded as a collaborative journey of sensemaking, which can be described as a process that involves the cooperation of all parts that compose an organization, in order to raise awareness and understanding from different perspectives and interests of their individuals. The culture of an organization has to be something in constant development, always shaping itself to the circumstances lived, as well as to the changes and to the evolution that occurs. So, whenever you decide to implement anything in your company, you should first think about your cultural roots. "It says that a crucial purpose of culture is to help orient its members to “reality” in ways that provide a basis for alignment of purpose and shared action."   Creating the perfect data-driven team by reshaping the one you already have Data analytics is probably one of the buzzwords of this century. Everybody wants to be part of a data-driven…

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Why real-time data matters for the packaging industry

I don't even think we should start this article by telling you the benefits of real-time data. The best approach is to begin by showing you what happens when you don't have it. A good way to explain this is to imagine a scenario where you're driving your car: not having real-time data is the same as looking through the rearview mirror while driving, without paying attention to the road. Can you imagine pilots, air traffic controllers, and airport managers relying only on data collected 12 hours ago? Or two weeks ago? They need to make decisions on real-time. It seems an exaggerated example (and it is), but it's just to make a point and warn you that your plant might be losing a lot of money if you keep on using data collected on paper and excel spreadsheets (which have become obsolete). Manufacturing plants that do not have real-time data are always one step behind of the resolution of any problem. Or worse, they are always one step behind of finding out they have a problem. Real-time data in the packaging industry (manufacturing) The evolution of technology makes changes happen at an ever-increasing speed and in…

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Read more about the article How To Get A High Engagement Level From Operators On A Production Line
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How To Get A High Engagement Level From Operators On A Production Line

*By Fernando Pacheco - COO at PackIOT First of all, I would like to make something clear: I don't wish this article to be another one of those "guru" posts that you read on the internet (10 things to do to keep your operator engaged).To write this text, I tried to compile the years of experience of our team of production specialists (at PackIOT), combined with my background as a manager and researcher. I really hope this can turn into something useful for you and your team. For whom this content is intended: line supervisors, shift coordinators, plant managers, industrial directors, business managers, operators, and future leaders. In a recent survey, TTI Global has released some choking data on engagement and satisfaction in the manufacturing sector. "According to these new insights - which canvassed employees across 11 industry sectors between December 2018 and 31st May 2019 - Manufacturing employees provided the lowest employee satisfaction score (7.4/10) overall".  Based on the data they have collected, they analyzed what Manufacturing employees expect, as well as what they value the most. The highest of these continues to be ‘Understanding what is required from you’ (39%), followed by ‘Support from your line manager’ (30%).…

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