The intelligent factory of the future: Focus on automation and data

The development of modern manufacturing processes is on the verge of a profound change: automation, artificial intelligence (AI) and real-time data processing are becoming increasingly important in the printing industry. The so-called 'smart factory' enables more precise and efficient production, reducing human intervention and avoiding production bottlenecks.

In the networked print factory, production data is collected in real time and stored comprehensively for long-term analysis. This continuous data collection and analysis is particularly valuable because it enables print service providers to identify recurring patterns and make targeted adjustments. Historical data also provides the basis for identifying bottlenecks early and preventing them from negatively impacting the production process. For example, companies can understand which machines are repeatedly reaching their limits with certain jobs, or which production steps are subject to delays. With this knowledge, processes can be optimised to improve efficiency and print quality.

Autonomous Mobile Robots (AMR) play a key role in the smart factory. They can automatically move material to and from production lines without the need for dedicated aisles that many older models require. These robots interact seamlessly with workers because they have sophisticated safety features that prevent collisions. In practice, this means that AMRs can independently load presses with new print materials and transport finished printed products to the next processing step.

The new technology also enables production jobs to be grouped into optimised batches. This significantly reduces makeready times between jobs, as similar jobs can be processed together. An intelligent system automatically decides which jobs belong together, helping to optimise the production flow. This automation minimises human error and increases efficiency through better utilisation of the production lines.

Another key benefit of the Smart Factory is quality assurance: It uses AI-based systems to scan and analyse printed sheets during the production process. Based on this analysis, the system automatically decides whether adjustments need to be made to ensure quality. This reduces the need for human intervention, as the system can detect and correct most errors on its own.

At drupa 2024, HP showcased its end-to-end Print OS solution, demonstrating how innovative production technologies can add value to intelligent print factories. These systems enable seamless monitoring of production lines and offer a high degree of flexibility to respond to individual customer requirements. From ordering and printing to finishing and shipping, all processes are networked and can be customised for specific applications.

Implementing the Smart Factory presents companies with technical challenges. But change management is at least as important! Many companies already have cutting-edge technology. But moving to automated processes requires rethinking at all levels and a willingness to challenge established processes. Only those who rise to this challenge will be able to reap the long-term benefits of the smart factory and future-proof their production.

In an era of ever-increasing production volumes and faster turnaround times, the role of data and automation in the printing industry is becoming increasingly important. Businesses that embrace these cutting-edge technologies will increase their efficiency and be able to meet the challenges of the marketplace while leaving their competitors in the dust.