ERP for plastics processing, injection moulding and composites
Moulds and cycle counters, tool changeovers, regrind incorporation rates and OEE: the ERP that runs a workshop where performance is decided by the second of cycle time.
- Moulds, cavities and counters
- Preventive maintenance on the counter
- Tool changeovers and SMED
Tooling is your real production asset
In injection moulding, capacity is not counted in presses but in press-and-mould pairs. A four-cavity mould on an available press is not worth the same as a two-cavity mould: the output rate changes, and so does the unit cost.
A mould wears by the cycle, not by the calendar. Its preventive maintenance is triggered once a cycle count is reached, and a counter kept by hand drifts within a few weeks. An unanticipated tooling breakage stops an entire part number, sometimes for months.
Then comes the question of tool changeover. Every changeover is production time lost, and that is precisely what the SMED method attacks. Changeovers still have to be measured to know which ones are worth the effort.
Material, between traceability and incorporation rate
Material arrives as pellets in batches and is blended in the hopper with regrind from your own sprues and rejects. The incorporation rate is a contractual figure on some parts, and a cost figure on all of them.
What actually goes into the part must therefore be traced: virgin material batch, proportion of ground regrind, and colourant batch. Without it, a customer complaint cannot be contained and is settled by a widened recall.
AVIA ERP keeps the cycle counter per cavity, triggers preventive maintenance at the threshold, measures tool changeover times, calculates OEE per press and traces the incorporation rate down to the batch produced.
What a plastics processing workshop expects from its ERP
- Moulds, cavities and countersTooling fleet management, cycle counter per cavity, location and availability, history of interventions.
- Preventive maintenance on the counterMaintenance routines triggered by cycle count reached rather than by date, with the tooling reserved.
- Tool changeovers and SMEDChangeover times measured per press-and-mould pair, internal and external operations distinguished, gains achieved tracked.
- OEE and cycle timeOverall equipment effectiveness per press, deviations from the theoretical cycle time, downtime analysis by cause.
- Material and regrind traceabilityVirgin batch, proportion of ground regrind and colourant batch tied to the part produced, with an incorporation rate that is controlled and retrievable.
The direct benefits for your industrial company
No more tooling breakage from counter drift
Maintenance is triggered on the real cycle, reported by production rather than entered by hand.
Tool changeovers that are measured
SMED is applied where the gain is real, because the times are at last known per press-and-mould pair.
An OEE that is calculated, not estimated
The deviation from the theoretical cycle time is read per press and per shift, together with the downtime causes.
A complaint contained to the right batch
Material traceability avoids widening a recall for want of knowing what went into the part.
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