PackIOT carries a market survey for the packaging industry

It reveals half of the packaging industries don’t track their productivity in real-time

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A survey results for productivity and OEE goals of companies in the packaging industry, Photo by PackIOT
A survey results for productivity and OEE goals of companies in the packaging industry, Photo by PackIOT

The market survey carried out by PackIOT, in partnership with Instituto das Embalagens (Brazil), 360 Packaging (India and Asia), and People of Packaging (USA), reveals that more than half of the packaging producing industries are unable to point out in a time where are the bottlenecks in the production line. More than 150 packaging industry professionals from over 25 countries participated in the survey, concluding that 12% of companies say that identifying bottlenecks and analyzing correct data is a struggle.

Another fact revealed by this research is that 82% cannot point out trends in their products among the packaging industries. This is mainly due to the fact that almost a third of these industries use manual systems to identify problems or monitor their KPIs. Almost half of the sectors control the equipment downtime manually, with the operators filling in the data.

PackIOT comments on monitoring OEE goals of the factories

The study carried out worldwide by PackIOT also shows that two out of three companies do not have the means to monitor and track their factories’ productivity and OEE goals in real-time. Half of the industries only have access to this information at certain times.

The OEE (Overall Equipment Effectiveness) is one of the main metrics that allows monitoring the equipment performance, as it analyzes equipment availability, performance, and quality. It is noteworthy that industries that use cloud-based solutions, 63% of respondents, have better control of their factory’s production metrics, such as OEE, setup time, and wastage rates, compared to industries that do not use cloud solutions. These responded that they use manual processes for data collection in a proportion four times greater than companies with cloud solutions.

Another relevant point is that only 35% of companies can guarantee that they are reaching productivity goals. Just over half of packaging factories can respond, using the tools and systems they have in their factories, to how their production is running at that particular moment. On average, nearly two out of three factories do not know when peak production is. The best shift occurs when the highest scrap rate and whether they are on schedule for planned downtime.

The Digital Maturity Survey in the packaging industry revealed that more than half of the factories still use spreadsheets (such as Excel) to analyze data. One in four industries collects data manually. Real-time data can help your packaging plant to have better people management, new business opportunities arising at the right time, better decision making, and quick responses to alerts. Despite this, only 18% of industries collect data across the entire shop floor, and nearly 30% have real-time data available.

“Everyone is talking about Industry 4.0 today. Many agree that this should happen, but few know what this expression really means or even know where to start. To help us better understand how the packaging industry is doing within Industry 4.0 and digital transformation, we have developed our new Digital Maturity in the Packaging Industry study”, says PackIOT chief executive officer Cristiano Wuerzius.”

“While moving towards digital transformation may seem difficult, there are simple steps the packaging industry can take and prepare to experience Industry 4.0. Chief executive officers, plant managers, shift leaders, and operators can now create the right environment for success.”

 

The Covid-19 pandemic led to the country-wide lockdown on 25 March 2020. It will be two years tomorrow as I write this. What have we learned in this time? Maybe the meaning of resilience since small companies like us have had to rely on our resources and the forbearance of our employees as we have struggled to produce our trade platforms.

The print and packaging industries have been fortunate, although the commercial printing industry is still to recover. We have learned more about the digital transformation that affects commercial printing and packaging. Ultimately digital will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future.

Web analytics show that we now have readership in North America and Europe amongst the 90 countries where our five platforms reach. Our traffic which more than doubled in 2020, has at times gone up by another 50% in 2021. And advertising which had fallen to pieces in 2020 and 2021, has started its return since January 2022.

As the economy approaches real growth with unevenness and shortages a given, we are looking forward to the PrintPack India exhibition in Greater Noida. We are again appointed to produce the Show Daily on all five days of the show from 26 to 30 May 2022.

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– Naresh Khanna

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