In an injection moulding shop profit depends on how many shots a machine produces and how healthy the tool is. Which machine is waiting for a tool change, which is down, how many shots a tool has run and how much granulate was scrapped get lost in shift logbooks. In the system we build, work orders are planned with machine and tool pairing, and the operator enters start, downtime reason and good and scrap counts on the tablet at the machine. The tool shot counter signals when maintenance is due, and resin consumption and OEE are reported by shift.
Problems we see in moulding shops
- Reasons for machine downtime not recorded
- Tool maintenance not done by shot count
- Resin and masterbatch scrap unknown
- No way to predict when an order will finish on which machine
Modules
Machine scheduling
Placing work orders on the machine, tool and shift calendar.
Tool management
Cavity count, cycle time, shot counter and maintenance history.
Machine-side screen
Entry of production start, downtime reason, good and scrap counts.
Raw material use
Use of granulate, masterbatch and regrind, and scrap.
Quality control
First-off approval, dimensional checks and non-conformance records.
OEE report
Machine efficiency from availability, performance and quality.
How it works day to day
- 1
An order becomes a work order and a suitable machine and tool are assigned.
- 2
The tool is fitted and first-off approval is given.
- 3
The operator enters counts and downtime on the tablet throughout the shift.
- 4
An alert arrives when the tool shot counter nears its maintenance limit.
- 5
At shift end a consumption, scrap and OEE report is produced.
Integrations
Off-the-shelf software or custom-built?
When off-the-shelf is enough
For small shops with a few machines, the production module of an ERP and shift forms may be enough to start with.
When custom software pays off
As the number of machines grows, a custom system that monitors tool life, downtime reasons and OEE in real time makes efficiency losses visible and lowers maintenance cost.
How the budget is built
We launch the workflow that saves you the most time first, then add modules based on real usage. The full scope below is calculated with 20 screens and 9 modules; the final price follows a free discovery call and a written scope.
Maintenance and improvements (optional): €550 / month. Hosting, SMS, WhatsApp and app store fees are listed separately.
Frequently asked questions
Can shot counts be taken from machines automatically?
On machines with a suitable signal output, the cycle signal is read by an IoT device and counts and downtime are recorded automatically.
Can it be used on older machines?
Yes, on machines that give no signal, the same reports are produced from operator entries on the tablet.
Is tool maintenance history kept?
Yes, each tool’s shot count, faults and maintenance records are held on its own card.
How does it work with our ERP?
Orders and stock are taken from the ERP; production, consumption and scrap data are posted back.
