Plastic Products
Plastic Products: production orders and BOM, stock and warehouse, quality and reporting.
Challenges
- Cavity count and cycle time are missing from the product card, so capacity calculations never add up.
- The resin-to-masterbatch ratio is not tied to a recipe; colour inconsistency surfaces only later.
- Reground scrap fed back into production is not tracked in stock, so costs look higher than they are.
- Without mould maintenance and life tracking, the line stops in the middle of a run.
Workflows
From mould to production order
- The mould is registered with its cavity count, cycle time and linked product.
- The production order is opened with the machine, mould and target quantity.
- Resin and masterbatch are drawn from the recipe and deducted from stock.
From scrap to regrind feedback
- Flash and rejects are recorded as separate scrap items.
- The reground material is booked into the regrind stock.
- The regrind ratio is written into the recipe and the unit cost is updated.
Documents
- Mould card (cavity count)
- Production order
- Recipe (resin + masterbatch)
- Scrap and regrind slip
Reports
- Machine and mould utilisation
- Cycle-time deviation
- Scrap and regrind ratio
- Unit cost by product
Metrics
- Cycle time (seconds/part)
- Scrap rate
- Regrind usage rate
- Mould downtime
Compliance
- Food-contact plastics regulations
- Packaging waste and recovery declaration
- REACH chemical notification obligation
Glossary
- Cavity count
- Number of parts produced per shot, held on the mould card
- Cycle time
- Operation time that feeds the capacity calculation
- Masterbatch
- Colour or additive component entering the recipe at a set ratio
- Regrind
- Reground scrap booked back into stock
FAQ
Can I factor cavity count into capacity?
Yes — cavity count and cycle time are held on the mould card, and the production order computes capacity from them.
Can I tie the masterbatch ratio to the recipe?
Yes — colour and additive ratios are defined in the bill of materials and consumed at the same rate on every order.
Can I book reground scrap into stock?
Yes — regrind is its own stock item, and its usage ratio is stated in the recipe.
Can I plan mould maintenance?
Yes — the mould card keeps a shot counter and raises an alert once the maintenance threshold is passed.
Can I see unit cost by product?
Yes — resin, regrind, cycle time and machine cost are all gathered on the production order.
