How is mold management achieved?

WMS controls mold storage locations and history, combined with PDA barcode tracking for full-process visibility.

How does APS scheduling work?

Automatic scheduling based on machine capacity, mold availability and process rules; results directly drive MES dispatching.

Plastic Injection Molding Solutions

Established in 1985, the client specializes in household products with injection molding as its core process. To gain precise material demand visibility and improve financial transparency, the company deployed a data platform with BI dashboards connecting cross-department workflows. MES, APS and WMS were introduced alongside SAP ERP integration — vertically unifying scheduling, execution and inventory management to strengthen overall operations.

Industry Challenges

Frequent mold, machine and color changes make manual scheduling prone to idle time and changeover losses

Scattered storage of materials and finished goods causes time-consuming searches and stocktaking; mold history and location need systematic management

Paper-based or verbal work instructions lead to high training costs and inconsistent quality

Report consolidation is time-consuming, cross-department data is out of sync, hindering real-time decisions

Implementation Goals

Synchronize production plans with the shop floor: APS scheduling drives work orders and dispatching

Error-proofing: batch and serial barcode matching ensures consistent check-in/out and deduction

Precision warehouse and mold management: WMS-controlled storage locations with PDA operations reducing errors

Data-driven decisions: real-time KPI dashboards for WIP, achievement rate, OEE and traceability reports

Solution Overview

MES serves as the manufacturing data hub, integrating with APS, WMS and SAP ERP along with a data platform to connect the full flow: planning → dispatch → production → quality → warehousing → decision-making.

MES Execution

Integrates SAP, APS and WMS to enforce shop-floor control, reporting labor/machine hours and quality data. Retrieves master data from SAP, with APS supporting schedule adjustments for real-time information sharing.

WMS Warehouse Management

Enables storage location and mold management, improving inventory accuracy and reducing search time. PDA-supported receiving and put-away operations minimize errors.

Data Platform

A data hub and enterprise decision platform unifying heterogeneous system data into operational dashboards and reports for WIP, production achievement and equipment OEE.

APS Scheduling

Automated scheduling and capacity planning with schedule reports supporting sales and procurement meetings, reducing communication overhead.

Implementation Results

Quality Yield Improvement via MES

Barcode-scanned batch and serial verification against work orders — no pass, no release; synchronized check-in/out, reporting and deduction; real-time alerts on anomalies.

11%

Inventory Reduction via APS

Real-time shop-floor and warehouse status updates enable intelligent scheduling that reduces inventory and wait times, minimizing changeover losses.

50%

Warehouse Efficiency via WMS

PDA-optimized warehouse operations strengthen inventory and location accuracy; full-process mold visibility reduces search and changeover prep time.