Improving Energy Performance in Flexographic Printing Process through Lean and AI Techniques: A Case Study

Flexographic printing is a highly sought-after technique within the realm of packaging and labeling due to its versatility, cost-effectiveness, high speed, high-quality images, and environmentally friendly nature. A major challenge in flexographic printing is the need to optimize energy usage, which requires diligent attention to resolve. This research combines lean principles and machine learning to improve energy efficiency in selected flexographic printing machines; i.e., Miraflex and F&K. By implementing the 5Why root cause analysis and Kaizen, the study found that the idle time was reduced by 30% for the Miraflex machine and the F&K machine, resulting in energy savings of 34.198% and 38.635% per meter, respectively. Additionally, a multi-linear regression model was developed using machine learning and a range of input parameters, such as machine speed, production meter, substrate density, machine idle time, machine working time, and total machine run time, to predict energy consumption and optimize job scheduling. The results of the research exhibit that the model was efficient and accurate, leading to a reduction in energy consumption and costs while maintaining or even improving the quality of the printed output. This approach can also add to reducing the carbon footprint of the manufacturing process and help companies meet sustainability goals.