The plastics industry is very diverse, providing products to a wide array of markets. Many plastic and rubber companies have a combination of moulding and assembly operations and these two processes pose a different set of challenges.
The assembly operations need balanced processes to ensure labour and automated operations work together to maximize output. The moulding and extrusion processes are governed by cycle times, mould/die performance and energy consumption. The quality and mixing of the raw material can also have a profound effect on efficiency.
See below to find out which modules address the issues highlighted.
- User configurable Andon callout and production scorecard systems (GAIN4 Andon)
- Calculation of OEE by machine / asset and line (GAIN4 Efficiency)
- Ability to balance production across multiple assembly lines (GAIN4 Tracking & Efficiency)
- Detailed labour tracking and management (GAIN4 Labour tracking)
- Management of die changeovers and SMED activities (GAIN4 Alert & Andon)
- Full batch traceability (GAIN4 Tracking)
- Detailed real time Quality control and SPC (GAIN4 Quality & process)
- Production planning to minimize changed material effects (GAIN4 Planning)
Benefits:
- Improves process of making die changes
- Improves management of die quality
- Provides accurate and timely information to improve final assembly quality and efficiency
- Enables full product traceability at all stages of production
- Real time measures of efficiency, downtime and cycle times allows identification of areas for efficiency improvement
- Provides data to allow for better management of labour costs
- Improves management of moulding process temperatures
- Improves raw material mixing and quality