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EMAN Comprehensive Digital Solution for Mold Factories

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Intelligent Planning and Scheduling

Key Benefits

  • Delivery Commitment: Quickly make delivery commitments and capacity assessments based on scheduling strategies and order forecasts.
  • Change Response: Rapid response to plan changes with daily, weekly, or monthly plan updates, facilitating quick decision-making.
  • Inventory Reduction: Decrease inventory levels of raw materials and purchased parts, minimize obsolescence, and shorten the average inventory cycle of semi-finished products.
  • Mold Change Reduction: Use minimal mold changes as a scheduling constraint to minimize changeovers and reduce changeover time.
  • Color Change Reduction: Prioritize production with the same material, color, and machine to reduce mold cleaning losses due to color changes.
  • Automatic Order Splitting: Automatically split orders for production based on mold and preparation status, in line with delivery times and resource capacity balancing principles.

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Intelligent Production Management

Key Benefits

  • Comprehensive Quality Control: Ensure quality assurance with complete coverage of production process control and product traceability.
  • Efficient Anomaly Response: Real-time alerts and notifications for anomalies enable quick responses to minimize losses and ensure continuous production.
  • Equipment Management & Adaptability: Detailed daily inspections and maintenance reduce downtime; supports injection molding and equipment production management, catering to diverse production needs.

Scene

  • Equipment Data Collection
    • Smart Data Collection and Analysis: Utilize an industrial IoT platform for real-time collection and analysis of production process data, aiding in precise decision-making.
    • Error Prevention Parameters: Automatically record and send trial and mass production parameters with a single click to effectively prevent operational errors.
    • Reduced Skill Dependency: Automatically distribute injection molding parameters to lessen reliance on skilled technicians for machine adjustments.
    • Accelerated Changeovers: Automate robotic program deployment for quick model and production changes, enhancing production efficiency.
  • Integrated Mold and Injection Management
    • Collaborative Mold Management: Share mold parameters, manufacturing processes, and product data across integrated molding systems and synchronize business processes.
    • Break Down Information Silos: Enable cross-departmental, cross-factory digital collaboration for multiple processes through seamless information sharing.

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Edge Automation

Key Benefits

  • Automated In-Mold Part Removal: Features such as automated box changing, empty box delivery, and full box automatic AGV calling.
  • Automatic Parameter Input: Seamless one-click robotic program dispatch and automatic entry of process parameters.
  • Order-Based Production: Reduces overproduction and early production, while also minimizing dependency on skilled technicians for machine adjustments.
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Centralized Material Supply Management

Key Benefits

  • High-Precision Material Supply: Ensure accurate raw material ratios through precise control and measurement, enhancing production stability and product consistency.
  • Reduced Material Waste and Loss: Precise measurement of raw material usage prevents waste due to human error and over-supply, lowering production costs.
  • Efficient Production: Automated material supply and control reduce manual operations, enhance supply speed, and minimize downtime and adjustment time.
  • High-Quality Assurance: Dehumidification and drying treatments of materials ensure raw material quality, improving overall product quality.
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Intelligent Mold Warehouse

Key Benefits

  • Fully Automated Storage and Retrieval: Enables fully automated mold storage, retrieval, and delivery to injection molding machines, increasing efficiency.
  • Smart Scheduling: Automatically triggers mold retrieval based on changeover plans for precise coordination.
  • Efficient Space Utilization: Saves over 60% in floor space, with space utilization rates up to 90%.
  • Precise Management: Supports storage of thousands of molds, ensuring precise management and efficient operations.

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Intelligent Semi-Finished/Finished Goods Warehouse

Key Benefits

  • Fully Automated Operations: Achieves complete automation in storage, retrieval, and cross-floor distribution, with production schedules driving retrieval to enhance operational efficiency.
  • Customized Automation Handling: Supports automated customization of tasks like sorting, palletizing, and packaging, catering to diverse production needs.
  • Efficient Logistics Integration: Seamless AGV integration significantly boosts storage efficiency and reduces logistics time.
  • Space and Management Optimization: Combines high-density storage with precise inventory management, saving space and reducing error rates.

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Intelligent AGV Transport

Key Benefits

  • Dual-Effect Integration: Combines intelligent AGVs with an integrated scheduling platform to enhance transport efficiency through coordinated hardware and software efforts.
  • Smart and Flexible Scheduling: Utilizes an integrated scheduling platform for intelligent task allocation and efficient collaboration across multiple AGVs.
  • Autonomous Operation: Intelligent AGVs independently complete transport tasks, minimizing human intervention and reducing labor costs.
  • Adaptability to Diverse Scenarios: Capable of meeting the needs of different storage and production environments, enhancing the versatility and flexibility of logistics transport.

Scene

  • Intelligent AGV
    • Fully Automated Operations: Automatically handle tasks such as retrieving full boxes and supplying empty ones. The system intelligently coordinates the automated flow and inspection of injection molded parts, eliminating the need for human intervention.
    • Multi-Type Compatibility and Efficient Scheduling: Compatible with a variety of AGV types, such as stealth AGVs, with tasks allocated to the nearest available unit to boost logistics efficiency.
    • 24/7 Stable Operation: Supports continuous 24-hour operation; box change time alerts ensure smooth processes and uninterrupted production.
    • Seamless Integration and Unmanned Production: Seamlessly integrates with warehouses to enable unmanned production, reducing labor costs.
  • Integrated Scheduling Platform
    • Multi-Task Parallel Processing: Supports simultaneous multi-task processing.
    • AGV Intelligent Scheduling: Automatically selects the optimal AGV unit.
    • Dynamic Path Optimization: Calculates the optimal path and delivery time in real-time.
    • Priority Sorting: Optimizes delivery order based on time priority.
    • Traffic Control: Intelligently manages AGV traffic to prevent congestion.
    • Order Insertion Strategy: Supports dynamic insertion of urgent tasks.

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Intelligent Warehouse Management

Key Benefits

  • Barcode Precision Control: Utilize barcode management for accurate tracking and efficient operations throughout the entire warehousing process.
  • Comprehensive Material Management: Cover both raw materials and finished goods to ensure orderly material flow and clear data management.
  • Refined In-Warehouse Operations: Optimize internal management to enhance the efficiency of activities like inventory counting and sorting.
  • Coordinated Workshop Logistics: Strengthen logistics management within workshops to promote seamless integration and efficient collaboration between warehousing and production processes.

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Equipment Data Collection

  • Smart Data Collection and Analysis: Utilize an industrial IoT platform for real-time collection and analysis of production process data, aiding in precise decision-making.
  • Error Prevention Parameters: Automatically record and send trial and mass production parameters with a single click to effectively prevent operational errors.
  • Reduced Skill Dependency: Automatically distribute injection molding parameters to lessen reliance on skilled technicians for machine adjustments.
  • Accelerated Changeovers: Automate robotic program deployment for quick model and production changes, enhancing production efficiency.

Integrated Mold and Injection Management

  • Collaborative Mold Management: Share mold parameters, manufacturing processes, and product data across integrated molding systems and synchronize business processes.
  • Break Down Information Silos: Enable cross-departmental, cross-factory digital collaboration for multiple processes through seamless information sharing.

Intelligent AGV

  • Fully Automated Operations: Automatically handle tasks such as retrieving full boxes and supplying empty ones. The system intelligently coordinates the automated flow and inspection of injection molded parts, eliminating the need for human intervention.
  • Multi-Type Compatibility and Efficient Scheduling: Compatible with a variety of AGV types, such as stealth AGVs, with tasks allocated to the nearest available unit to boost logistics efficiency.
  • 24/7 Stable Operation: Supports continuous 24-hour operation; box change time alerts ensure smooth processes and uninterrupted production.
  • Seamless Integration and Unmanned Production: Seamlessly integrates with warehouses to enable unmanned production, reducing labor costs.

Integrated Scheduling Platform

  • Multi-Task Parallel Processing: Supports simultaneous multi-task processing.
  • AGV Intelligent Scheduling: Automatically selects the optimal AGV unit.
  • Dynamic Path Optimization: Calculates the optimal path and delivery time in real-time.
  • Priority Sorting: Optimizes delivery order based on time priority.
  • Traffic Control: Intelligently manages AGV traffic to prevent congestion.
  • Order Insertion Strategy: Supports dynamic insertion of urgent tasks.
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Industry Pain Points

Cost Control Challenges

Material waste, high labor costs prone to errors, and costly, lengthy equipment maintenance cycles together make it difficult to effectively control production costs.

Low Production Efficiency

Inefficient scheduling, extended equipment idle and wait times, and cumbersome, time-consuming mold change processes hinder overall capacity improvement.

Unstable Quality

Insufficient quality control during production, lack of effective traceability systems, and high-quality requirements from client audits contribute to unstable product quality.

Slow Decision-Making Response

Delayed anomaly alerts, weak rapid response capabilities, and lack of effective emergency handling mechanisms.

Inefficient Space Utilization

Outdated storage management and inefficient production layouts lead to finished or semi-finished goods inventory buildup, tying up capital.

Business Blueprint

The EMAN Injection Molding Full-Factory Digital Solution

The EMAN Injection Molding Full-Factory Digital Solution integrates lean manufacturing principles and connects enterprise resource planning (ERP) systems, product lifecycle management (PLM) systems, and more. It also integrates with underlying automation equipment PLC systems, providing comprehensive control over production elements such as personnel, machines, materials, methods, and environments in the workshop. This facilitates lean manufacturing and digital management for enterprises.

 

EMAN Related Solutions

EMAN Related Solutions

EMAN Advantages

  • End-to-End Digital Coverag

    Encompasses the entire injection molding production process, providing full lifecycle management from order to delivery.

  • Integrated Mold and Molding Collaboration

    Breaks down data silos between mold and injection workshops, supporting unified management of mold, injection production, and equipment coordination to avoid information isolation.

  • Intelligent Decision-Making and Efficiency Improvement

    Utilizes the APS system for real-time order scheduling and quick response to order changes, optimizing equipment utilization and reducing inventory backlogs.

  • Real-Time Transparent Production

    Implements equipment networking and data collection to monitor key indicators such as equipment OEE and unexpected downtimes in real-time, precisely identifying efficiency bottlenecks.

  • Comprehensive Quality Control and Traceability

    Integrates incoming material inspection, first article inspection, in-process inspection, and storage inspection to create a closed-loop quality system and establish a traceable knowledge base.

  • Industry Validation and Scalability

    Endorsed by leading companies and successfully applied in numerous enterprises across high-precision fields such as automotive, home appliances, and medical industries.

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