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Efficiency and Electronics
August 1, 2009 By: Chris Raney Paperboard PackagingIf you are about my age, you probably once had a car or truck that you worked on yourself, mine was a dark grey 1970 Mini.
 CHRIS RANEY |
By far the biggest difference between my old Mini and the vehicle I drive now is in the amount of electronics. The Mini had none to speak of, apart from in the radio, while my current wheels won't let me go anywhere until its onboard management system has ensured that I don't have worn brakes or my seat belt unfastened.
Beyond that there are an untold number of systems designed to make our vehicles run at optimum efficiency. They match the air/fuel mix to the conditions, adjust the power train and suspension to match the road and our driving habits and monitor maintenance schedules. Without these, we would use more gas, create more pollution and break down more often.
It's much the same with most modern production equipment. For example, the heart of the modern Bobst machine control is the CUBE unit. These systems reduce makeready times by recalling settings from previous jobs; speed up production by allowing the operator to make adjustments on the fly; improve performance and consistency by controlling key areas such as the infeed on a diecutter; and help with troubleshooting.
It's all about efficiency, getting the product where it needs to be with the least amount of waste. We can't forget the many sub-systems and optional components that feed into it. Typical of these would be the dynamic register control systems available on diecutters and hot-foil stampers.
These use sophisticated electronics, software, drives and mechanics to bring sheets into perfect diecut-to-print, or foil-to-print register, improving quality and consistency and reducing waste. The latest advances in these are bottom-reading cameras, which are ideal for the growing market in litho-laminated products.
Modern folder-gluers have also taken advantage of innovative electronics. Systems like those for gyroscopically turning boxes on the run or applying Braille, rely on communication between control systems like CUBE and fast, responsive servo motors. These have taken over where maintenance intensive chains and v-belts previously prevailed. They not only do a better job, but allow modern folder-gluers to be more productive, versatile and consistent.
Possibly the most forward looking application of electronics in modern lines is the way they can be interfaced to create communication routes and workflows. Machines can now be connected to the internet, allowing a remote technician to view the status of the machine and troubleshoot machine faults or production problems without the delay of travel.
On top of this, production machines can now be quickly, easily and securely interfaced opening a vista of information on performance and status to those who need it — be they on the shop floor, elsewhere in the plant or anywhere in the world with an internet connection. The information can even be sent direct to a PDA.
For those who need a fast, accurate, and coherent exchange of information between shop floor and a company management information system (MIS) or enterprise resource planning system (ERP), it is now possible to connect these and your machines together. This has clear advantages for those who want to streamline workflows — but beware that the solution you choose is fully JDF compliant. Like high definition TV — JDF is coming.
Technology has certainly changed the way we do business. If we look back 15, or even 10 years, and consider how much more we can accomplish today in fewer production hours, with less waste and lower overhead, it is quite remarkable isn't it? Looking to the future and the innovation and technology on the horizon... I think we can rest assured the trend will continue.
Chris Raney is vice president, Folding Carton products for Bobst Group North America, Roseland, N.J. He is responsible for the Folding Carton Business Area for the North American market. He can be reached at christopher.raney@bobstgroup.com.
