Digitalization in the Packaging Industry: Reduced Downtime, Continuous Improvement

78 % First Print achieved – significantly fewer downtime through automated data collection in production

In the world of flexible packaging, every second counts – and every color. For production managers in the printing industry, this is a daily challenge: They struggle with expensive test prints, time-consuming setup times, and the ongoing question of how to simultaneously increase quality and efficiency.

Here, a leading manufacturer with over a dozen locations in Europe explains how, with smart machine data, it has not only increased the number of successful first prints – but also strengthened the culture of responsibility and agility in production. An example that shows how production data platforms can ease everyday operations and deliver real results.

Initial Situation: Test Prints as a Cost Factor

In the printing process, the initial print is crucial. This is where it is checked whether the print quality is correct – before production starts. Ideally, one initial print is sufficient to confirm the settings. However, if an order requires multiple initial prints, the following increases:

• Material consumption,

• Setup times, and

• Costs – especially due to expensive inks and specialty coatings.

The goal is therefore clear: to print “First-Time-Right” as quickly and often as possible to avoid unnecessary costs and losses.

Process before ENLYZE: Good approach, but time-consuming

Even before ENLYZE, the team was working on process improvements. The proportion of perfect first prints increased from 60 % (2017) to 70 % (2023) through continuous improvements – a remarkable success in the printing industry.

However, the analysis required for continuous improvement was manual and slow:

• Initial prints were time-consuming to document and analyzed in monthly meetings

• Causes for additional initial prints could only be identified with delay

• Process improvements could not be implemented flexibly and promptly

More perfect first prints through transparency and real-time analysis

The printing shop manager set ambitious goals:

1. 75 % of orders should already be successfully completed in the first print

2. To identify problems and their causes faster through real-time process monitoring, and

3. To implement targeted adjustments immediately

Printing process digitized – less downtime, more quality

With the ENLYZE Manufacturing Data Platform, the printing process was comprehensively digitized. The process data from the gravure printing machine is read from the controls of the system, processed, and made available through the ENLYZE app.

The collected data and the accompanying process monitoring help to improve print quality, as well as increase the effectiveness and efficiency of the entire production process.

A highlight: automatic downtime recording. The Manufacturing Data Platform automatically detects downtimes. Operators can quickly and easily comment on them and then focus on solutions. At the same time, the ENLYZE platform offers a digital preparation of the print data, so they can be reviewed and discussed within the team on the same day.

The result: 78 % first print, faster process optimization

With ENLYZE, the team exceeded the target of 75 % and achieved 78 %. This impressive improvement was made possible by faster feedback loops and increased awareness among employees. The digital preparation and commenting function for downtime recording facilitated a more efficient analysis of challenging orders, so that adjustments could be implemented more swiftly.

Orders that previously required multiple initial prints are now usually optimized on the same day. A positive change in workflows became noticeable:

• Higher efficiency through faster analyses and direct team discussions

• Increased sense of responsibility among employees

• More targeted process adjustments

Next steps: 80 % first print and stable processes

The team aims to further increase the share of first prints to 80 % through sustainable standardization of all processes with ENLYZE.

"With ENLYZE, we have found a solution that not only saves us time and costs but also provides continuous support for our team in everyday operations. Having a digital companion for manufacturing is now indispensable."
– Head of Printing & Color Warehouse

Experiences and success secrets for digitalization in manufacturing

• Automated data collection: Switching to digital machine data collection saves time, frees the shift team from manual documentation, and provides precise real-time data.

• Cultivating continuous improvement to a new level: The direct availability of data increases accountability and fosters motivation among employees.

• Faster process adjustments: Through the continuous availability of data, improvements can be implemented immediately, and their effectiveness can be measured rather than waiting for monthly meetings.

• Sustainable process optimization: ENLYZE helps to easily identify root causes of errors and permanently eliminate them through targeted measures.

Saving time and costs with a culture of continuous improvement

What advantages would it bring to your production if you truly utilized machine data — instead of just collecting it?