A mold tech at a high-volume automotive injection molder watches 32 presses from a tablet. Cavity pressure on press 14 drifts 2% over an hour — nothing triggers a scrap alert, but by shift's end, 640 parts have short-shot flash hidden in the trim pile. At $4.20 per part, that's $2,688 in hidden scrap. The real cost? The press ran good parts for 56 minutes before anyone caught the drift. No operator saw the OEE tick down. No dashboard flagged the trend. In molding, the gap between "running" and "running well" is measured in microns and milliseconds — and most plants can't see either.
See every press, every cycle, every loss — from one screen
iFactory ingests mold-machine, auxiliary, and vision data at the edge, computes OEE per press per cycle, and surfaces downtime, speed loss, and quality events before the stack cools.
iFactory is not another dashboard on top of a PLC. It is an on-premise, AI-native platform that captures every cycle event — injection time, hold pressure, cavity temperature, clamp force, cooling time — and computes OEE at the edge in real time. No cloud upload, no data egress, no IT project. The platform connects to any injection molding machine (Engel, Arburg, Husky, KraussMaffei, Milacron, Nissei, Toshiba, Fanuc) via OPC-UA, Euromap 77, IO-Link, or direct PLC tag mapping. It ingests auxiliary equipment (chillers, dryers, mold temp controllers), vision inspection results, and CMM data. The output is a single, live OEE number per press — availability, performance, quality — plus the root cause of every minute of lost production.
One platform. Every press. Every loss.
Six capability groups that turn cycle-level data into plant-wide visibility — no spreadsheets, no manual boards, no guesswork.
Live OEE per press, per mold, per shift
OEE computed every cycle — availability from planned vs actual run time, performance from ideal cycle time vs actual, quality from scrap counts. Trended by mold, press, part number, and operator. Drill from plant OEE to a single cavity in two clicks.
Root-cause downtime tracking
Every stop event is classified automatically — mold change, setup, material out, maintenance, operator break, jam, fault code. No manual entry. Pareto charts per shift, per press. Alerts when downtime exceeds a configurable threshold.
Cycle-level quality tracking
Ingest vision inspection pass/fail, CMM results, and process parameter limits per cavity. Track first-pass yield, scrap rate, and rework by press, mold, and shift. Set process windows per mold and get alerted when any parameter drifts outside spec.
Cycle time & speed loss analysis
Compare actual cycle time to ideal (dry cycle + process time). Detect slow cycles, injection time drift, cooling time creep, and hold pressure variation. Know exactly which press-mold combination is losing minutes per hour.
Configurable real-time alerts
Set OEE thresholds, downtime duration limits, scrap rate limits, and process parameter limits per press-mold combination. Alert via email, SMS, on-screen, or API. Escalate if no one acknowledges within a configurable window.
Automated shift & production reports
Daily, weekly, monthly OEE reports per press, per mold, per department. Shift handoff reports with downtime summary, scrap count, and top loss reasons. Export to PDF or Excel. No manual data collection.
From sensor to OEE in under 200 milliseconds
iFactory runs on a local NVIDIA appliance on your plant network. No cloud dependency. No data leaves the facility. The pilot connects to 10–20 presses in 6–12 weeks and scales to your entire plant.
Connect
Plug into your plant network. iFactory discovers injection molding machines, auxiliaries, and vision systems via OPC-UA, Euromap 77, or direct PLC tag mapping.
Ingest
Platform captures every cycle event — injection pressure, hold time, cavity temperature, cooling time, clamp open/close, ejector stroke, fault codes — at edge speed.
Compute
OEE is calculated per press per cycle in real time. Availability, performance, and quality are trended by press, mold, part number, shift, and operator.
Act
Live dashboards, alerts, and automated reports give operators, supervisors, and plant managers the data to act before the next cycle completes.
What hidden losses cost per press per year
In a typical 32-press shop running 3 shifts, 6 days a week, the gap between "running" and "running well" adds up fast. Here is the annual cost of three common blind spots.
Unseen slow cycles
A 0.3-second cycle time drift per part on a 10-second cycle running 8-cavity tooling adds 2.5 minutes of lost production per hour. Over a year, that is 1,560 hours of lost capacity per press.
Unreported micro-stops
Five 2-minute micro-stops per shift (robot jam, material hiccup, ejector pin hang) that no one logs. 30 minutes per shift, 3 shifts, 6 days a week.
Late scrap detection
Process drift caught 40 minutes after it starts. At 8 cavities on a 12-second cycle, that is 1,600 scrap parts before the alert fires. One incident per week.
What plants see after 90 days on iFactory
Real results from injection molding plants running iFactory for one quarter. Your numbers will vary, but the pattern is consistent.
Your plant has the data. iFactory turns it into OEE in real time. Book a 30-min walkthrough and we'll show you live on your data.
Questions buyers ask about injection molding OEE
Stop guessing what your presses are doing
iFactory gives you live OEE per press, per cycle, from a single screen. No cloud. No data egress. Pilot in 6–12 weeks. Book a 30-minute walkthrough and we'll show you what your plant's data says.
