Increase OEE by 9% with production management software

KROSCHU faced a significant challenge: the manual documentation of tool history for over 600 active tools. Every process step, from the initial set-up to the first good part, was recorded. This process required a lot of resources and was prone to errors. It also involved numerous handwritten records and Excel planning sheets.

A solution had to be found to replace this tedious process. The decision was made when KROSCHU discovered the MES solution authentig at a trade fair. In 2019, the software for machine data acquisition was introduced, gradually replacing manual data maintenance.

The reasons for implementing a production management software were complex:

• Efficient digitalization and automation of documentation processes

• Minimize sources of error and improve quality assurance

• Free up valuable resources

• Transparent real-time process tracking

• Seamless traceability of every process step

ENGEL authentig...

• is a Manufacturing Execution System (MES) software.

• was specially developed for the plastics industry.

• enables the collection of data on machines and production. This revolutionizes operational production management.

• provides the foundation for strategic planning and control of production with the collected data.

• has a modular structure. Various functions can be implemented as required.

At KROSCHU, all injection molding machines were networked with the introduction of the production management software authentig. A total of seven terminals were installed to facilitate easy interaction between the machine operator and the system. These terminals allow for displaying order start and stop times, as well as all necessary documents for the respective production project. In addition, a central terminal in production provides a clear overview of the current status of the injection molding machines.

The acceptance at KROSCHU has been strong from the very beginning with all employees. The web terminal simplifies daily workflows and increases efficiency in production. This paves the way for a modern, data-driven production.

The elimination of manual work steps has created significant advantages in day-to-day work:

• Repetitive manual calculations of downtime are no longer necessary.

• Potential sources of error are drastically reduced.

• Process steps are directly recorded in authentig.

• Items are assigned unique numbers for identification.

• Seamless transfer of production data into authentig for customer orders.

Each cycle of the injection molding machine is recorded automatically. This optimizes error detection by trained employees and provides additional quality monitoring.

Authentig not only increases efficiency, but also improves the accuracy and reliability of the entire production process.

The Maintenance module plays a decisive role at KROSCHU, as it has a significant influence on communication with the toolmaking department. 

By creating a project, all relevant information is available for toolmaking at the same time. This not only saves a considerable amount of time, but also ensures a high quality standard and high tool availability. Especially with regard to audits, immediate answers, this enables immediate responses to auditor inquiries. 

A key aspect is the implementation of defined maintenance plans, which are stored in the production management software. Maintenance intervals are automatically monitored based on recorded production hours. This enables maintenance work to be announced at an early stage. This allows for early notification of maintenance work, preventing machine downtime due to unplanned mold maintenance. 

KROSCHU’s products are sold internationally. As a result, complaints often arise weeks after the completion of a production batch.

This is where authentig provides significant support. The production management software can seamlessly trace the existing dataset. This allows for precise analysis of deviations from the desired condition. The cause can also be identified, such as changes to the machine parameters or defective material.

The Quality Process module monitors process values in real time. Alerts in the monitoring system and push notifications indicate changes in machine parameters or cycle times.

ENGEL's custom-developed app enables 24/7 process monitoring. Thanks to this continuous monitoring, KROSCHU can react immediately if process data deviates from the defined tolerance ranges. This ensures that technical personnel are available on every production day to eliminate errors.

Read more about the successful process optimization following the introduction of the Manufacturing Execution System (MES) authentig at a plastics processor in technical injection molding.

The Order Management module controls short-term capacity planning. It covers a production window of two weeks.  

With this module, forecasts can be made, providing early insight into whether additional shifts are necessary to cover peak demand. This promotes efficient machine utilization and helps optimize labor and energy costs. 

With the Reporting module, KROSCHU receives important key performance indicators (KPIs) and statistics from production, such as scrap rates and machine downtime.  

The setup sends the settings data for each item to the machine, and this data is stored for every article.