Injection Molding Industry

The injection molding industry is a typical discrete process industry with its own particularity and complexity. The production mode of multiple varieties, small batches or even single pieces requires frequent new product development, and product design is one of the main activities of discrete manufacturing The manufacturing process is complex, and the correlation between various manufacturing processes in production is very strong. The probability of changes to the overall production plan is very high, and the production environment is complex and volatile. Last-minute order insertions and material shortages are common during the production process. The product production cycle is significantly affected by the production cycle of key equipment. In summary, order delivery time is mainly determined by the large number of product models, a large number of process steps, a small number of commonly used materials, multiple order batches, small order lot sizes, and machine capacity.

Industry Status

Challenges

· The procurement cycle for injection molding materials is short, resulting in high pressure on delivery dates for injection molded products.

· The frequent insertion and modification of orders makes scheduling and modification very difficult.

· The machine directly determines production capacity, and scheduling is directly tied to the machine.

· The BOM configuration structure is complex, making management difficult.

· Multiple products can be produced at once, resulting in occasional mold jams.

· Injection molding manufacturing is complex to manage and difficult to accurately track.

· Mold management requires strict requirements.

· Post-molding processing management and scheduling are difficult to keep up with.

· Outsourced processing cannot accurately predict time and output, making management difficult.

01. Equipment Maintenance Management

Provides equipment maintenance and servicing plans and generates reports, enabling automated maintenance reminders and performance evaluations, providing a basis for production scheduling.

02. Production Report Management

Automatically, promptly, and accurately generates various reports, providing scientific tools for improving equipment efficiency, process improvements, and quality enhancements.

03. Production Process Management

Real-time recording of each mold's actual molding parameters (machine cycle, labor cycle, temperature, and pressure) ensures traceability of product quality and mold adjustment parameter history.

04. Quality Management

Compare actual process parameters to facilitate problem tracing and analysis. Statistics and analysis are also performed on the various causes of defective products during the production process.

05. Production Scheduling

Integrated with the ERP system, work orders are automatically generated and, after review, assigned to the appropriate machines for reference by workshop QC, foremen, machine repairmen, and material handlers.

06. Real-Time Production Monitoring

By networking the workshop's machines, the MES system provides real-time visibility into the production status of each machine in each workshop, material consumption, the progress of each work order, and alarms regarding production anomalies.

07. Equipment Data Collection

Connecting production equipment in the workshop to the network enables real-time, accurate, and objective collection of production site data, enabling accurate and accurate handling of any anomalies.

Orbit-MES Solution

Customer Value

Improve Manufacturing Execution Capabilities

Provide data support for production efficiency, cost, and quality analysis, improving the company's manufacturing execution capabilities and product delivery capabilities.

Improve Decision-Making Accuracy

Help companies improve data accuracy and real-time performance, and improve production decision-making capabilities through data-driven decision-making.

Reduce Costs And Increase Efficiency

Shortening production cycles, reducing inventory backlogs, and lowering defective product rates, effectively helping businesses achieve cost reduction and efficiency gains.