As manufacturers begin to integrate these new systems, many questions arise about how they will affect the organization and how the organization should adapt to this impact. It is important to understand that scientific shaping depends on the strategic implementation of data collection systems. Failure to record information carefully will not only reduce the company's ability to successfully replicate production operations, but will also lead to inconsistent conversions and ultimately lead to production capacity failures.
For the requirements of modern production systems, injection molding companies face greater challenges than other manufacturers. Reproducing successful operations is the key to financial success: more than 400 potential metric changes can occur in a typical molding process, which can lead to scrapping, inefficiency, and unplanned downtime. Industry 4.0 record able media can quickly provide better information resources, thereby eliminating stiff methods and increasing profits.
This article will outline the basic concepts of the Industry 4.0 monitoring system. It will also define how, if used properly, they can increase the total output while minimizing the adverse effects on ordinary plastic injection production systems.
Overcoming resistance to change
Many companies started the journey of implementing the Industry 4.0 system by asking a simple question: "How does the system drive the performance indicators of my plastics plant?" Axio Group, a Canadian supplier of automotive OEM molding services, has developed an internal system Efficiently use many other plants to produce high-quality parts in your own way. Practice has proved that the Industry 4.0 method is a solution to eliminate speculation in its automotive production environment.
Promoting the Industry 4.0 standard through new processes at all levels from production to leadership is undoubtedly a challenge. People at all levels resist change,
There is no doubt that workforce training is essential to ensure the success of data recording and process verification. The production environment requires a collage of people from different backgrounds and experiences. Each job category has its own set of rules and metrics to define the success of the department.
It is important to understand that each methodological approach requires a learning curve, which must be patiently recognized and followed. The due diligence of managers must first focus on training all employees on how to use Industry 4.0 procedures and the application of scientific molding principles. After training must be monitored to ensure that production personnel understand and implement the strategy being implemented.
World-class performance is not easy to climb-many necessary steps must be taken to reach the top. True process standardization can only be achieved by establishing key indicators that define the repeatability of success. These same metrics can be used to identify changes in the established production system. The Industry 4.0 system, tailored to the specific needs of plastics processing facilities, can quickly provide key measurable indicators while expanding the amount of data available for comparison.
The company's success depends largely on how it handles unplanned maintenance, downtime, and scrap. The paper data recording system prevented the company from identifying real-time losses in real time. The company found that it relied on incomplete and potentially corrupt data, which was often identified long after the fault was resolved. The management has left the office banking business in the hope that production off duty will continue to produce parts at night.
Imagine being able to reduce the machine's downtime by half and solve the problem immediately through real-time root cause analysis without having to react to it after hours or days. The Industry 4.0 system adds this feature to your molded arsenal. Production evaluation and solutions do not require a week of information collection to determine problems and formulate solutions, and decisions need to be made as quickly as necessary.
For decades, manufacturers have been using paper-based systems to monitor production metrics, schedule production runs, and view performance and output. This manual production report allows the company to look elsewhere for continuous improvement. It also created a false analogy: "Why repair undamaged things?" Initially, this assumption would make the argument for the Industry 4.0 system more challenging than originally expected. When the company began to trespass to integrate the Industry 4.0 system, this would never be a completely smooth transition. In fact, it may be a battle that seems more difficult than expected.
But this is not necessarily daunting, and it doesn't even have to be overly ambitious. This will require some planning and implementation. Humans are habitual animals, so asking them to change the way they operate over the years will require a well-thought-out process that involves working with system vendors to develop strategies and implement these strategies to monitor their effectiveness. After all, your employees will use these new systems to increase their productivity-you need their support to ensure that the potential of the system is fully utilized.
As many vendors provide managers with new digital gateways to access their data, the management team that was trying to introduce five different Industry 4.0 systems to bury them and their team in the information was taken aback. Any system must centralize all data points and have only one goal-to make life easier for the employees of the organization through speed and accuracy. If too many systems are introduced at once, it is almost impossible to get support from employees.
Key indicators in injection molding
Of course, according to organizational needs and production requirements, the measurable injection volume will be different. Use process, tool, maintenance and production managers to determine the key factors that will affect your overall production success. This is a basic list that outlines many of the indicators that define the basis of solid formation:
Benefits of staged introduction
There is a simple reason why the introduction of new technology in stages is effective-it promotes change at a certain pace so that all questions can be answered before the technology is promoted to all employees. One of the biggest risks companies face when deploying systems too quickly is that the "change management" aspect of the technology is lost among employees. There will be questions: some sound repetitive, some answers are simple, and some are not. The role of the manager is to promote business development in the most effective way, while integrating a system that will provide employees with unprecedented tools.
As our industry increasingly focuses on reducing inefficiencies in each area, time is the biggest waste in every organization. The Industry 4.0 production monitoring system can completely eliminate the time allocated for collecting production indicators, while generating detailed information. By providing quick information, managers can quickly determine the root cause of production problems when problems occur. Return on investment (ROI) is the key for management to control the production system. By providing employees with new tools, ROI monitoring is easier to analyze, thereby reducing response time.
Stage 1: Start small and start big. Work with your Industry 4.0 system supplier to develop a successful integration strategy. The supplier needs to know exactly what your monitoring target is, so it is up to you to ask the relevant questions:
Phase 2: Let department heads speed up the use of new tools and let them use the simplest functions first. Advocate the system internally and provide them with knowledge. Make the most of your relationship with system vendors, but do n’t rely on them for every answer-they do n’t know your employees like you.
Some key strategies implemented:
Phase 3: Full deployment. Now you can buy from the department head, it is time to promote the system across the company. The person in charge of each department is designated as a system expert. You also need to monitor the progress of skill integration within each group under their guidance. Continue to generate reports, use new information, and ask each employee how they use the system.
Work with suppliers to deliver active feedback and fine-tune all aspects of the system to make them more ingrained in employees' daily work.
After the launch, please ask the supplier to use your own data to determine ROI and introduce improvement measures to your employees. Similarly, this opportunity should also be used to consider employees' own KPIs and use their success through the system. In this way, people will be able to actively use these data to achieve their work performance and daily work gains.
Important strategies for maintenance:
In terms of production methods, plastic injection molding is a challenge. Application of Industry 4.0 system will quickly provide a rich source of historical data. This method is essential for any science-based company. It will continue to provide the key information needed to ensure an orderly and standardized approach. The success of any company depends entirely on the amount of information data available and the speed of access.