Project Background
The client is a mid-sized injection molding factory specializing in automotive plastic parts, with 60 injection machines. As order volumes grew rapidly, the old scheduling model—reliant on shop floor supervisors' experience—became unsustainable: machine downtime was opaque, process parameters lived only in technicians' memories, defect tracing required digging through paper records, and quality incidents often meant significant losses.
The client wanted an MES that stitches together order, scheduling, production, quality, and delivery—giving management real-time visibility into every machine and shift on shop-floor dashboards.
Core Challenges
- Equipment status was a black box—problems surfaced only 30 minutes after a stoppage
- Scheduling relies on the supervisor's experience, with chaotic process parameters on change orders.
- Quality issues cannot be traced to the specific shift or mold.
- Paper-based timesheets drag out finance cycles.
Solutions
A three-layer MES architecture—data collection, business process, and visualization. Start with device IoT, then roll out scheduling and quality, and finally light up shop-floor dashboards for full transparency.
Production Scheduling
Order-driven Gantt scheduling supports fast re-planning on change orders.
Device Data Collection
IoT gateway captures real-time status from 60 machines.
Process Dispatch
Standard mold parameter library deploys to machines in one click.
Quality Traceability
End-to-end traceability from batch number to shift, mold, and process.
Workshop Dashboard
Real-time dashboards for output, OEE, and defect rate.
Work Hour Tracking
Auto-aggregate crew hours and feed payroll calculation.
Implementation Results
Want to learn about our manufacturing MES solution?
Dedicated consultants conduct on-site surveys for tailored solutions.
