Making paper digital

The Körber Business Area Tissue is moving ahead full steam with Industry 4.0 and smart factory projects. One of the company’s developments involves a digital monitoring system for the tissue sector that will significantly increase efficiency.

Into the future with “Tissue Data”: Luca Frasnetti, Chief Technology Officer in the Körber Business Area Tissue.

Körber has an ambitious goal: It’s looking to establish a new culture in the tissue industry and support its customers, such as toilet paper and paper towel manufacturers, as they move into the digital future. “Industry 4.0 and digitization are still not the top priority at all the companies in our sector,” says Luca Frasnetti, Chief Technology Officer at the Körber Business Area Tissue. “We therefore want to lead the way and develop innovative solutions that exploit the opportunities of digitization — solutions that convince our customers that the new technologies offer them tremendous potential.”

lWe want to develop innovative solutions that exploit the benefits of digitization — solutions that convince our customers of the tremendous potential offered by the new technologies.r

Luca Frasnetti, Chief Technology Officer in the Körber Business Area Tissue

Körber Lab: A digital ecosystem for the tissue industry

The tissue specialists from Körber work closely with the Körber Business Area Digital. The two organizations are conducting numerous projects that explore the potential offered by new digital technologies. A key role is also played here by the recently established Körber Lab. This open innovation hub is not just for Tissue employees to use. Instead, it views itself as a digital ecosystem for the entire tissue industry in the region. Design thinking and agile methods — the Körber Lab is first and foremost a more collaborative facility that coordinates cooperation and an exchange of ideas with start-ups, universities, suppliers, and various institutions, including the Centers of Excellence for Industry 4.0 that have been established by the Italian government.

Smart Machines, Smart Software, Smart Services

The Körber Business Area Tissue, which is headquartered in Lucca, Italy, is systematically pursuing a single vision with all of its digital activities: a network of factories linked with one another in which customers can use intelligent hardware and software to realize networked production — perfect in terms of both quality and business results. The Körber Business Area Tissue is stepping up its activities to a tremendous extent in order to rapidly transform this vision of Industry 4.0 into reality. The associated Digital Tissue™ concept is made up of three closely linked components (Smart Machines, Smart Applications, Smart Services) whose interaction forms the foundation for the establishment of a Smart Factory.

lThe data that’s collected and evaluated in a fully connected cross-factory environment represents a treasure of immeasurable value.r

Luca Frasnetti, Chief Technology Officer in the Körber Business Area Tissue

Design thinking, agile methods — the employees at the “Körber Lab” rely on a strongly cooperative style of working.

Tissue Data: An innovative monitoring system

The digital triad is made possible by the continual collection of huge amounts of data (big data) throughout the running production process. Körber’s Tissue Data software application shows the possibilities big data can offer when it’s converted into smart data. This innovative monitoring system makes it possible to save, analyze, and transfer large amounts of production-process machine data from all of the modern converting and packaging machines used in the tissue industry.

Customers can use this information to further increase the efficiency of their facilities, for example. Technicians at customer plants can use a touchscreen monitor to quickly and easily view all information about unplanned machine downtime via a mobile device, regardless of whether the technicians are in their office or directly onsite at the production line. “If a machine suddenly shuts down, the technician can immediately identify the cause and permanently remedy it, simply on the basis of the data that has been stored and prepared for analysis by our software,” Frasnetti explains. “That prevents the recurrence of unplanned manufacturing shutdowns,” he adds.


A detailed overview of the entire production line

As if that weren’t enough, Tissue Data also enables customers to gain a complete detailed overview of their downtimes, rate of production, and rejects. As a result, tissue companies now have a tool that for the first time ever makes the most important key performance indicators of a production line transparent on a large scale. For example, this tool enables customers to compare planned production figures with actual production results and identify the causes of any deviations. In other words, Tissue Data creates ideal conditions for aligning production processes more efficiently and further optimizing individual production steps. That in turn permanently improves the operational effectiveness of an entire facility.
However, according to Frasnetti, Tissue Data can only develop its full potential if the vision of Industry 4.0 becomes a reality. “The data that’s collected and evaluated in a fully connected cross-factory environment represents a treasure of immeasurable value,” says Frasnetti. “Its use would catapult our customers’ production processes into a completely new dimension.” Körber plans to continue supporting its customers along this digital path and to do everything in its power to ensure that smart factories become a reality.

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