Smart Automation End of Line – Part 1: Is the Finishing Line the Final Frontier?

By Mathieu Tremblay, Managing Director, IMPACK, Canada

On a printing press or die-cutter, a sheet is a sheet. It comes in a predictable, consistent size. It flows through the process the same way every time. But once the blank gets to the folder-gluer, variability increases exponentially. Each box type is processed differently, and each presents its own challenges.

We’ve always depended on human adaptability to navigate variability. But in the current labor context, these job positions are becoming harder than ever to fill. Repetitive tasks, especially with heavy products, introduce safety issues and increase the risk of repetitive strain injuries. Understandably, people aren't eager to do physically demanding work. Additionally, humans have natural speed limitations, which cap capacity on the line. Unlike printing and die-cutting, which are largely automated, the end-of-line in the finishing department is still highly manual and also the most complex to automate. The good news is that Smart Automation in the finishing department, especially end-of-line, eliminates heavy lifting and unlocks the higher speed and capacity your line was built for.

Why Smart Automation?

Automation in the finishing department is often talked about as a goal to reach, but in reality it’s a journey that requires careful planning and preparation long before equipment is selected or installed. Many automation projects struggle not because of the technology itself, but because the underlying processes, data, and organizational readiness weren’t fully considered from the start. This is exactly why we call this approach Smart Automation: it prioritizes understanding constraints, aligning people and processes, and making informed decisions before investing in technology. Taking time to lay the groundwork properly allows manufacturers to move forward with clarity and realistic expectations. This sets the stage for improvements that actually deliver value.

This article explores how to prepare for that journey by focusing on system readiness, process stability, and people as much as machines. Rather than chasing maximum automation it emphasizes organizational readiness, understanding production realities, and building a strong data-driven business case. By establishing this foundation, you can make smarter decisions about where automation will have the greatest impact today, while positioning yourself for more advanced solutions tomorrow. Part 2 will build on this foundation by identifying bottlenecks, examining common finishing-line scenarios and the levels of automation best suited to each.

Laying the Groundwork for your Automation Journey

Think of automating your facility as a journey rather than a destination. Smart Automation often starts by analyzing the system and pinpointing the greatest bottleneck that’s limiting the speed of the process. Solving one bottleneck often reveals the next greatest bottleneck. As you progressively automate, you increase safety, efficiency, and capacity.

Automation is as much about people and processes as it is about machines. It’s a gradual shift that involves technical adaptation and human transformation. Every automated task affects a web of connected processes — from machine setup and production planning to staffing, metrics, and even the way success is defined. 

What Companies Must Consider 

Here are five key areas that affect the success of automation projects in complex manufacturing environments: 

1. System Integration :
   Can your ERP and MES systems communicate with the automation hardware? Are your workflows digitized, or will you create data silos? 
2. Process Readiness :  
   Is your current process standardized and repeatable? Or are you at risk of automating chaos? 
3. Organizational Readiness : 
   Are your teams trained and supported for this change? Has change management been planned? Do you have internal “automation champions”? 
4. Flexibility vs Throughput:
   How much variation does your operation require? Semi-automation excels in high-mix, frequent changeover environments, while full automation favors long, stable runs.
5. Total Cost of Ownership (TCO) :
   Look beyond the purchase price: consider installation, training, safety compliance, maintenance, as well as expected uptime and increase in capacity.  Additionally, review the impact this will have on staffing.

Planning your Journey

The first step in any automation journey should be a thorough process map. As you work through your automation journey your objective is to progressively improve it. This will require working toward major process transformation milestones. As automation increases, it doesn’t just change equipment—it reshapes how the operation functions day to day.

• Machine set-up and changeover
• Crew roles and skill requirements
• Scheduling of people and products
• Quality control
• KPIs and performance evaluation
• Production volume (grouped by similar box types of similar sizes)
  • Number of boxes per run
  • Number of runs per week or month
• Downtime
  • Due to make-readies
  • Linked to labor instability
  • Due to preventative and unplanned maintenance
• Total labor cost on the finishing line
  • Crew
  • Number of shifts

To manage the logistics of the transformation, you’ll need data. The initial data you collect becomes the foundation for a solid business case for automation. While automation projects can appear costly at first glance, many manufacturers discover that payback is achieved far sooner than expected once all variables are considered.

To accurately assess return on investment, analyze your current production using the following factors:

In part 2 of this article series, we’ll talk more about using this data to assess various automation solutions.

While automating physical tasks with AI is still a long way off, AI already plays a valuable role in planning and scheduling. Most finishing department managers do their best to consolidate box types on specialized folder-gluers – thus reducing downtime related to make-readies. Last minute orders, fluctuating orders and staff availability can derail the best laid plans! AI can be used to analyze large data sets to reveal patterns that support smarter decisions—both operationally and financially.

Start your Automation Journey

Smart Automation is not about pursuing the highest level of automation possible—it’s about making informed decisions that improve safety, stability, and performance where they matter most. In complex environments, success depends on aligning technology with real production needs, workforce realities, and long-term operational goals.

In this article, we’ve outlined a practical way to evaluate automation readiness including what to consider, where to focus, and how to think beyond the “dream of automation” toward smarter outcomes. Take this information to your team and begin preparing both your processes and your people for a successful automation journey.

If this assessment highlights gaps or constraints, address them collaboratively with your team. Gather the data needed to understand your current reality. In part 2 of this article series, we’ll help you define your final destination by exploring real-world finishing-line scenarios. For each scenario, we’ll outline the level of Smart Automation that has helped others optimize performance and increase capacity. These examples will help you identify situations that mirror your own operation and provide a practical blueprint for moving forward with confidence. With this information you’ll be able to develop and present a clear, defensible business case for a strategic investment in automation.

Footnote: Photography by Jennyfer Monette, artwork by Dmytro Zhurov, copyright Conception IMPACK 2025