For data parameter management to be most effective, it is necessary to collect accurate data before, during, and after the manufacturing process at all times and in real-time. The parameters of plastic injection include molding conditions, equipment status, and environmental conditions. There are so many kinds of data to be collected. How can we obtain correct and correct data information without increasing the workload of front-line personnel?
The benefits and applications of data parameter management in each stage of plastic injection are explained. The data parameter management of plastic injection can prevent misuse of data parameters, improve machine adjustment speed, and ensure current production in each stage before, during, and after production quality. Assist in the retrospect of production history, predictive maintenance of equipment and molds, digital inheritance of knowledge, and optimization of data parameters.
We can consider using digital software system tools to collect and manage data parameters of plastic injection with technologies and methods of digital transformation, industry 4.0, and smart manufacturing, to make the plastic injection more digital, and intelligent and improve production efficiency. How to do it?
Real-time and accurate data is conducive to quality analysis, exception reporting, and elimination
In the production process, only by mastering all-around real-time production data parameter data can we eliminate and deal with problems as soon as possible in the early stage of occurrence of problems and stabilize product quality. For example, if it is found that the filling time deviates from the control boundary, it should be stopped immediately for an inspection. And the problem should be eliminated immediately, to reduce the cost of personnel, materials, and equipment utilization rate reduction caused by the production of a large number of defective products.
However, a complete record of injection molding conditions requires a lot of items to be filled in, which often results in an explosion in the workload of on-site personnel. Moreover, the plastics industry, especially the daily-use plastics industry, employs more than one person and multiple machines. If the data is still recorded manually, it is difficult to fill in the data at any time. Usually, the recording is completed at one time after the production is completed, which will also make the data changes during production more difficult to be recorded completely.
The illegible handwriting and the authenticity and correctness of the data are also problems. In addition, the machine has a lot of sensor data, all of which change in seconds, which is more difficult to record manually. At present, the plastics industry relies on the experience and operation of professionals to adjust the molding conditions and machine parameters in the process from sample to mass production. Data and parameter records are mostly recorded manually in paper or Excel. If the record is wrong due to negligence. When abnormal quality occurs, it will be impossible to trace the source correctly and analyze the root cause due to incorrect records.
Use IoT to create a production environment that automatically records real and reliable real-time data
How can we reduce the burden of on-site personnel, and can keep abreast of equipment and production conditions at any time, and grasp important and real-time data on-site? Make it easier and more convenient for field personnel to report back.
Using digital software system tools, with the technologies and methods of Industry 4.0 and smart manufacturing, that is, the Internet of Things and the Internet of Machines technology of IoT, the most real-time data of the equipment is collected, and the data is transmitted to the database for storage through the network. Even if it is a traditional machine device without a communication interface, it can be collected by IO hard wiring or by adding a sensor to complete the networking. Field personnel can also use the mobile phone or tablet app to enter data painlessly with simple and intuitive operations.
After various data are integrated with the digital software system tools of the related systems on the manufacturing site through the IoT/Internet of Things. These complete and reliable data can be immediately transmitted to the mobile phone, computer, or dashboard of the corresponding person in charge, so that the People who need data to help with decision-making, no matter where they are, can grasp everything instantly and quickly.
By integrating the data parameters in the production process with the information of the relevant systems on the manufacturing site, after the data is integrated. In addition to allowing the manufacturing site personnel to grasp the changes of various data parameters at any time; when an abnormality occurs, the manufacturing site personnel who are busy with one person and multiple machines, the problem can also be found and solved immediately. The order and schedule affected by the abnormality can be confirmed immediately, and subsequent corresponding adjustments can be made immediately.
The fusion of these long-term accumulated data can build a data model of big data. In the future, it will be helpful to optimize data parameters, improve yield, and perform predictive maintenance/predictive maintenance of equipment and molds. Better production quality and more stable production capacity. It makes the factory smarter and achieves the digital transformation of the manufacturing industry.