Track mould life and ownership, multi-cavity production (shots × cavities × cycle time), virgin / regrind / masterbatch BOM, and cycle-time variance per machine per shift - all in one cloud system.
Tally and BUSY handle accounting. SAP and Microsoft Dynamics need 4-month implementations. Neither is built for these specific plastic injection moulding units pain points:
Moulds cost ₹2-50 lakh each. Track which mould is on which machine, expected vs actual shot count, last maintenance date, and whether the mould is yours or customer-owned. Without this, mould failures kill production and customer disputes about mould ownership go unresolved.
A 4-cavity mould produces 4 pieces per cycle. Cycle time 28 seconds = 514 cycles/hour = 2,056 pieces/hour at 100% efficiency. Production planning must use this math. Manual calculation per machine per shift is error-prone.
Grade ABC: 70% virgin + 25% regrind + 5% colour masterbatch. Customer specs constrain regrind %. Cost per kg of finished material depends on virgin rate, regrind value, masterbatch rate. BOM must compute this for every shot.
Every cycle produces sprue + runner waste, which is reground in-house. Regrind kg flowing back into stock must be tracked, allocated to grade, and reused per spec. Otherwise, you either run out of regrind or stockpile useless regrind.
When a new mould is on its first tryout, the rejected parts and over-cycle-time are tryout cost, NOT production cost. Mixing the two distorts product cost. ERP must classify mould tryouts as a separate cost center.
Machine X running mould Y at 32-second cycle time today vs 28-second standard = 13% productivity loss. Without machine-shift level cycle-time capture, you don't know the loss exists until month-end variance.
Here is exactly what we will show you in a 30-minute demo. Every screen uses real industry workflows, not generic sample data:
Each mould has: ID, owner (you / customer name), cavity count, expected shot life (typically 500K-2M shots), shots done to date, last service date, location. Mould approaching 80% life triggers maintenance schedule.
Grade ABC for customer X: 70% virgin (HDPE, rate ₹125/kg), 25% regrind (in-house regrind, rate ₹70/kg), 5% colour masterbatch (rate ₹450/kg). Blended cost per kg auto-computed. Customer specs (max regrind %) enforced.
Order 50,000 pieces of part XYZ on 4-cavity mould. System calculates: 12,500 shots needed. At 28 sec/cycle, that's 5,833 minutes = 97 hours of machine time. Schedule on machine #5 across shifts.
Each injection machine logs cycle time, shot count, and downtime through machine sensors (or operator screen if no sensors). Dashboard shows live: machine #5 running, mould Y, shot 4,238 of 12,500, cycle 28.3s vs std 28s.
End of shift, operator weighs sprue + runner regrind generated. System logs regrind kg by grade. Stock master shows live regrind inventory by grade. MRP for next production blends regrind first (within spec).
When a new mould is mounted, the production order is flagged 'tryout'. All material consumed and parts rejected during tryout post to a tryout cost centre, not the customer's product cost. Customer-billable tryout time (per contract) is tracked separately.
For each customer mould, monthly statement shows: mould #, location (your floor / their warehouse), shots done, expected life remaining, maintenance status, parts produced this month. Customer gets transparency; ownership disputes vanish.
Availability × Performance × Quality per moulding machine per shift. Six Big Losses breakdown: changeover time, breakdowns, minor stops, reduced cycle, startup scrap, production scrap. Variance vs target visible in real time.
Out-of-the-box features (no custom development needed):
Customer-owned moulds segregated from your moulds. Maintenance schedule by shot count.
Blend ratios with rate-effective tracking; customer-spec regrind % limits enforced.
Cavities × cycle time × shifts = realistic production plan.
Real-time cycle and shot capture from machine PLC or operator entry.
Sprue + runner regrind tracked by grade; reused per spec.
Availability x Performance x Quality with Six Big Losses breakdown.
Indian regulatory requirements handled natively:
An injection moulder in Pune
95 employees, ₹38 cr turnover, 24 injection machines, auto components + appliance parts
"Mould life tracking surfaced ₹6 lakh of unplanned mould failures in the first 4 months - failures we'd have caught earlier if we'd been counting shots. Now maintenance is scheduled by shot count, not by 'we'll get to it.' Downtime due to mould failure is down to almost nothing."Measured outcomes
Yes. Each mould has expected life (shots), shots done to date (auto-incremented per production), and a percentage remaining. Alerts at 80% trigger maintenance planning. Customer-owned moulds are segregated from your own moulds.
When you create a production order, the system uses cavity count from the mould master × cycle time from the mould-machine combination. 4-cavity mould at 28s cycle = 514 cycles per hour = 2,056 pieces per hour. Planning is realistic, not theoretical.
Yes. Each material grade has a blend ratio: virgin %, regrind %, masterbatch %. Customer-spec limits (e.g. max 20% regrind for automotive) are enforced. Blended cost per kg auto-computes from current rates.
End-of-shift, operator weighs the regrind generated and posts to the system. Regrind is added to grade-specific regrind stock. MRP for next production uses regrind first (within customer-spec limits), reducing virgin material consumption.
Yes. Modern moulding machines with OPC-UA or MODBUS interfaces can push shot count and cycle time directly into ERPDrive. For older machines, operator entry via tablet captures the same data with one screen per shift.
Each mould master has an 'owner' field. Customer-owned moulds are segregated; you can run monthly mould-ledger statements per customer showing location, shots done, maintenance history, and life remaining. Ownership disputes are eliminated by transparency.
OEE = Availability × Performance × Quality, calculated per machine per shift. Six Big Losses breakdown: changeover, breakdowns, minor stops, reduced cycle speed, startup scrap, production scrap. World-class is 85%; Indian SME injection moulders typically run 45-60%.
Free 30-minute personalized demo using your actual products, BOMs, and pain points. Scheduled within 24 hours.