Georgia-Pacific is implementing an internally developed AI platform, Digital Mezzanine, across its paper converting operations to analyze machine data and identify opportunities for performance improvement.
Adam Dunigan,
creator of Digital MezzanineThe system collects continuous data from converting equipment across multiple facilities, analyzing when, why, and for how long machines enter fault states. Its focus is not only on identifying downtime, but on determining which issues can be addressed to generate measurable results.
Referred to as “compressible opportunities,” these are identified by comparing fault data over time and across machines and facilities. The platform distinguishes between issues that are part of normal baseline operations and those that fall outside expected conditions and can be improved.
This approach differs from traditional methods that prioritize top losses, which may include recurring issues that cannot be fully eliminated. Instead, the system focuses on opportunities with demonstrated value.
One example involved a palletizer fault caused by a slip sheet lost by a gripper. By analyzing the product being run and comparing current fault patterns with historical data, the system determined that the frequency of faults exceeded expected levels. Based on this rate, the system projected a significant increase in stop conditions over a 24-hour period if the issue continued.
Once a fault pattern is identified, a large language model draws on machine manuals and technical documentation to generate troubleshooting steps specific to the failure mode. These recommendations are reviewed by senior technicians and subject matter experts to ensure safety and feasibility before being provided to operators.
Georgia-Pacific reports that facilities using Digital Mezzanine have achieved an average 15% improvement in machine efficiency with limited initial investment. The company is expanding deployment across additional machines and extending the platform to other Koch companies, including Guardian.
The system is intended to help operators and engineers identify and address issues more quickly, allowing problems to be resolved before they develop into larger operational impact
Georgia-Pacific is a U.S.-based manufacturer of tissue, packaging, pulp, paper, building products and related materials. The company operates a large network of manufacturing facilities across North America and is part of Koch Industries.
