In the world of packaging technology, adaptive manufacturing is changing the rules of the game. As a technology partner of the Barcelona Packaging Hub, B&R offers innovative solutions that take industry flexibility to a whole new level. But what exactly is adaptive manufacturing and when is it the best option for your company? In this article, we’ll explore how this approach optimizes overall equipment efficiency (OEE) and helps companies stay one step ahead in today’s competitive marketplace.
What is adaptive manufacturing and when is it the best option?
Adaptive manufacturing goes beyond traditional flexibility, offering a revolutionary approach to production. According to Wlady Martino, global packaging segment manager at B&R, “If your factory is optimized to produce large volumes of identical products day in and day out, adaptability will not make a significant difference. However, if production diversifies with more batches and customized products, investing in an adaptive solution becomes very cost-effective in terms of time, cleanliness, training and labor costs.”
When you manage multiple batches or need to customize products for e-commerce, adaptive manufacturing becomes a profitable investment. Reduced changeover times and staff efficiency are just some of the advantages.
As Wlady mentions, it becomes crucial in situations such as:
- Work with mixed batches simultaneously on the same production line.
- Customize products for e-commerce platforms.
- Take advantage of market trends by launching new products quickly.
Adaptability vs. flexibility: What makes adaptive manufacturing different?
Flexibility in manufacturing has been an important pillar for optimizing productivity and economies of scale. However, with ever-changing consumer demands, adaptive manufacturing takes flexibility a step further. It is now possible to switch from one batch to another effortlessly, even instantaneously, thanks to full control of each individual product on the line. This not only opens the door to managing unplanned products, but also to working with multiple SKUs (stock keeping units) within the same batch.
Rather than simply being flexible within certain limits, adaptive manufacturing removes those barriers, posing new opportunities and challenges. Key technologies such as mechatronic transportation, robotics, machine vision and simulation are fundamental to achieving this adaptability, creating an environment where products are manufactured, assembled and packaged in a more efficient and customized manner.
Improving OEE: Availability, Performance and Quality
Adaptive manufacturing is key to improving overall equipment efficiency (OEE), and it does so by acting on the three main factors: availability, performance and quality.
- Availability: Reduced downtime for changeovers gives you more time for productive operation. In addition, individual tolerance control and the ability to automatically skip faulty stations improve efficiency.
- Throughput: Thanks to parallel processing and workflow optimization, throughput can be multiplied without the need for plant expansion.
- Quality: With the help of electromagnetic diverters and advanced machine vision systems, you can improve quality by detecting and removing debris faster.
Case Study: B&R and adaptive manufacturing in packaging
A B&R customer in the packaging industry implemented adaptive manufacturing in its labeling process. Using the ACOPOStrak linear conveyor system, they were able to make the production line adaptable to any bottle format, regardless of its shape, size or label type. The flexibility achieved not only improved current efficiency, but also prepared the company to handle unplanned products in the future, ensuring a profitable long-term investment.
You can see how they did it in this video:
Packaging Technology as a Driver of the Future
B&R, as a technology partner of Barcelona Packaging Hub, helps member companies take full advantage of the benefits of adaptive manufacturing. This technology not only provides the flexibility your production needs, but also ensures that you are prepared to face any challenge, from mass customization to the introduction of new products to the market.
Ready to take your packaging technology business to the next level? Contact Barcelona Packaging Hub and find out how our experts can help you achieve your goals.
