BluePrint Automation (BPA) introduces Smart Industry. This Industry 4.0 technology goes a step beyond simply collecting data. The platform combines hardware, software, and specialized services to analyze downtime more quickly and to keep packaging lines performing at a consistently high level. It is available on new machines and, in certain cases, can also be added to existing lines depending on the age and configuration of the software. For several machine families, availability will follow later this year.
After the installation of a new packaging line, teams work intensively during the Site Acceptance Test (SAT) to achieve the desired performance. Afterwards, efficiency often declines again. Small disturbances accumulate, temporary fixes become routine, and in the rush of daily operations, deviations creep in. Smart Industry was developed to break this pattern.
The system collects data from sensors, operator input, and short videos of downtime events. This information is stored locally and can be forwarded to BPA. Specialists analyze the data, identify root causes, and discuss improvement points with the customer.
While many Industry 4.0 initiatives mainly focus on visualizing data, Smart Industry deliberately goes further. Data and dashboards alone do not deliver improvements. Finding the causes also requires in-depth knowledge of machines, line configurations, and processes.
“Most manufacturers simply do not have the people in-house who can consistently free up time for line improvement,” says one of the project leaders at BPA. “We combine data analysis with knowledge of the machine and the line, and translate that into concrete recommendations.”
Thanks to this combination, Smart Industry provides more than just insight: it offers direction for structural improvements and sustainable efficiency.
The first applications show that production lines can maintain or even improve their SAT performance. Video recordings make it possible to immediately review malfunctions, without operators having to wait until an error occurs again.
“That saves an enormous amount of time,” says an operator of a line where Smart Industry is already running. “We no longer have to search for a problem that might only occur once a week. The video footage immediately shows what happened.”
The system also makes clear which downtime events cost the most in terms of output. By comparing data over longer periods, patterns become visible and teams can address the main causes in a targeted way.
Smart Industry consists of three components. The hardware captures data and images using cameras, local storage, and industrial computers. The software provides dashboards for operators and analysts. The service component includes regular feedback sessions, monthly performance reviews, and annual visits to ensure improvements are firmly anchored.
Customers can choose hardware only, hardware with software, or the complete combination including service. It is especially in this last option that the platform’s strength becomes apparent, as data, knowledge, and practical experience come together.
Smart Industry does not stand alone, but connects with other BPA services such as inspections, preventive maintenance, training, and remote support. Together, these services support the performance and reliability of packaging lines throughout their entire lifecycle.
This is a translation of an article originally published in Dutch on Verpakkingsmanagement.nl.
Link to original article on verpakkingsmanagement.nl