Smart Factory: IoT-based production management
A production platform that collects real-time data from injection molding machines and combines live monitoring, Gantt planning, advanced reporting and predictive maintenance with end-to-end MES + MRP.
- 16data points / machine
- 3 spolling interval
- MES + MRPone platform
Canlı makine izleme
Vardiya A · 08:00–16:00basınç düşük
bitiş 11:20
From machine to decision: real-time production
IoT-based production management: real-time data from injection molding machines, end-to-end MRP and advanced reporting.
All machines on one screen, in real time
- Live OEE and outputShift target, scrap rate, cycle time and energy consumption, live.
- Process parametersNozzle temperature, pressure and cycle trend on every machine card.
- Smart alarmsFault codes, process deviations and mold changes are reported instantly.
- Maintenance trackingMaintenance planning with shot counters and predictive alerts.
Finite-capacity production planning with Gantt
- Machine & mold matchingAutomatic assignment by tonnage, cavity count and mold compatibility.
- Real-time progressOrder progress and due-date risk fed by machine counters.
- Mold changes & maintenanceSMED times and planned maintenance are placed in the plan automatically.
- AI optimizationSchedule suggestions that minimize mold changes and delays.
Advanced reporting from machine data
- OEE componentsAvailability, performance and quality by machine, shift and product.
- Loss analysis (Pareto)Downtime causes are classified automatically, clarifying improvement priorities.
- Scrap & qualityScrap causes and product-level quality rates.
- Energy efficiencyEnergy per part and detection of inefficient machines.
Predictive maintenance with AI
- Temperature profileNozzle and barrel zones monitored against process limits.
- Live process valuesPressure, clamping force, cushion and cooling time.
- Failure predictionThe model flags degradation trends days before a failure, with probability.
- Alarm & event historyEvery event is time-stamped and traceable.
Injection molding machines
- Modbus TCP
- OPC UA, EUROMAP 77
- EUROMAP 63
- Manufacturer MES APIs
Data collector (edge)
- High-performance C++ service
- 3-second polling interval
- Local buffer during outages
- Encrypted API transfer
Data platform
- Time-series database
- Rules & alarm engine
- MRP / ERP integration
Smart applications
- Live monitoring & TV mode
- Gantt planning
- OEE & loss analysis
- Predictive maintenance
16 data points read per machine
End-to-end production management: MES + MRP
Proven in the field
Built for plastic injection molding and recycling plants.
- Recipe-based, multi-warehouse, lot-tracked structure
- Role-based access: planning, operator, warehouse, quality, sales
- Ready for customer portal and e-invoice integration
- Web, mobile and desktop (tablets on the floor)
- Cloud or on-premise deployment
Questions about Smart Factory
If you cannot find the answer here, send us your question and the relevant specialist will get back to you.
Ask a questionWhich machines is it compatible with?
Data is read from injection molding machines that support Modbus TCP, OPC UA, EUROMAP 77 and EUROMAP 63, or manufacturer MES APIs.
What data is collected from the machines?
16 data points per machine are read every 3 seconds: machine status, cycle time, shot counter, nozzle, barrel and mold temperatures, injection pressure, clamping force, cushion, energy consumption, fault code, mold opening time and cooling time.
Is data lost if the connection drops?
No. The on-site data collector buffers data locally during an outage and transmits it encrypted once the connection is restored.
Is it only monitoring, or also production management?
It provides end-to-end MES + MRP: orders and quotes, production planning, bill of materials, stock and multi-warehouse, lot and barcode, recycling, assembly, shipping, quality control, maintenance management, demand forecasting, and staff and shift management.
How does predictive maintenance work?
Temperature profiles and live process values are monitored continuously; the model flags degradation trends days before a failure, with a probability. Shot counters and predictive alerts feed into the maintenance plan.
Is it deployed in the cloud or on site?
Both are possible: in the cloud or on a server inside the factory. It can be used on web, mobile and desktop, and on tablets on the shop floor.
Other solutions
Let's talk about Smart Factory
Tell us what you need, and we will get back to you with a solution architecture and proof of concept (PoC) tailored to your organization.