Industry 4.0 Plastic Injection Molding: Networking & Analytics

Technology in the manufacturing industry today isn’t just about how well a machine works, but how well it connects to other systems. In Industry 4.0 plastic injection molding, that means machines that don’t just inject plastic into molds but work together with sensors, controllers, and other systems to optimize operations, analyze processes, and even design better parts and molds. Today, let’s look at the unsung heroes of these powerful systems: their networking and analytics capabilities.

Early Networking and Internet of Things

To understand the step up that Industry 4.0 is, it’s important to recognize what came before. Many older systems still have “smart” capabilities, many of which worked through the system known as the “Internet of Things” or IoT. You may have these at your business or home, where systems share some information via a network connection to you or even other devices. However, these systems were often limited in what they share and even more limited in what they can control remotely.

Networking in Industry 4.0 Manufacturing

In Industry 4.0, equipment networking isn’t an afterthought; it’s a core part of the smart systems manufacturing machines have, which are built to be more integrated than ever before. There are some key components these types of systems have:

• Controllers: Primary machines, such as injection molding machines, have their brains in the form of Controllers. These machines control every aspect of the machine and act as the networking hub. To learn more, see our write-up about the Injectvisor V70 Controller on our Shibaura EC-SXIII.
• Sensors: Beyond complete control over all systems, robust sensors also track, measure, and record everything these machines do when they operate, from temperatures and pressure to cycle times. These can be used with analytics and learning systems (see below).
• Networking: These systems are designed to work directly with many systems out-of-the-box, including manufacturing execution systems (MES) and enterprise resource planning (ERP) systems. Combined with their ability to interface with robotics systems, this gives them more opportunities for optimization and efficiency.

Manufacturing Analytics and AI Learning

These smart systems also enable manufacturers to use data and computing power to optimize manufacturing for greater efficiency. Learning systems can analyze as the machine works, optimizing cycle times and speeding up mold set-ups for higher productivity and efficiency in machines and robotics. AI systems can help detect and remedy part defects, as well as predict maintenance needs for the mold and machine. This information can also be used forward when it comes to part design and mold creation, utilized by both customers and mold makers alike. It’s important to note that Industry 4.0 systems can go even further, reducing waste and increasing manufacturing sustainability while lowering costs. And these systems can benefit you today, even with your existing mold. Here at Midstate Mold, we have over 60 years in the plastic injection industry but also utilize the latest in AI learning, networked systems, and robotics. Contact us today to learn more and utilize the best technology plastic injection has to offer.