At 7:30 AM, the shift change occurs in the injection molding workshop. The molds from the previous shift have just been removed, and the molds for the new work order have not yet been installed. Workers flip through folders to find the corresponding work instructions, while line leaders run back and forth between several machines to swap drawings. This situation is very common in mold factories—molds are changed frequently, and SOPs must be updated even more often, making paper documents unable to keep up with the pace. A complete mold factory solution focuses on fully connecting the link between "mold number—SOP file—station terminal."
1. Mold Binding and Quick Changeover Functions
This is the most critical aspect of a mold factory solution. The approach involves establishing a binding relationship between the mold number and the SOP file within the system. By entering the mold number into the all-in-one terminal, fuzzy search is supported, allowing relevant work instructions to be retrieved in one second. Workers do not need to remember file names or ask line leaders; they can simply input a few digits to begin work. For injection machines that run a single mold for extended periods, IE or PE personnel can push the entire line configuration from the management end, requiring no action from workers during the process. Consider a hypothetical scenario: if a hardware injection factory typically stops the line to find files and verify versions each time a mold is changed, this solution estimates that the changeover preparation time can be reduced to the minute level.
2. Terminal and Permission Management Functions
The mold factory solution implements detailed features on the terminal side. An 18.5-inch narrow-bezel all-in-one machine designed specifically for compact workstation spaces in mold workshops was introduced in 2023. The system supports automatic logout after 12 hours of inactivity on the all-in-one terminal. Shift changes require login via employee ID, and operation logs are recorded throughout the process, showing who accessed which SOP and at what time. Page permissions can be assigned by role; for instance, the process parameter page is hidden from operators but accessible to technicians. Multi-language support includes Simplified Chinese, Traditional Chinese, English, and Vietnamese, which is useful for export-oriented mold factories. Essentially, these functions address the questions of "who can view," "how much can be viewed," and "whether there is a record after viewing."
3. Kanban and Remote Monitoring Functions
The Kanban module consists of an Android 4G industrial control computer box connected to a television. Data entry is initially performed via PC, with the capability to upgrade to semi-automatic or fully automatic data collection later. The IP box supports remote viewing from any location globally via PC, mobile phone, or tablet, with controllable permissions. Suppose a mold factory has established a branch plant overseas; headquarters can monitor the status of SOP retrieval at branch stations and production lines directly through a mobile phone. In this mold factory solution, the Kanban is not a standalone screen but is linked to the ESOP platform. Changeover actions, work order progress, and exception calls are presented on a single interface.
4. System Integration and Extension Functions
The mold factory solution reserves five integration methods: API interfaces, shared database docking, message queues, file transfer, and WebService. After an ERP or MES places an order, the system can automatically trigger a changeover, ensuring the SOP follows the work order without manual intervention. Regarding deployment selection, terminals under 100 units can use WiFi, but industrial-grade routers with AC controllers and APs are required; consumer-grade routers have low standby capacity and power, making them unsuitable for workshop environments. For scales involving tens of thousands of units, wired connections are the most stable option. A server with 4 cores, 8GB RAM, and 500GB storage can support approximately 300 terminals; expanding the hard drive allows support for over 500 terminals. The database starts from MS-SQL 2012.
5. Free Service and Support System
When selecting a mold factory solution, it is recommended to first clarify your own changeover frequency, mold quantity, and terminal scale, and then check off the modules listed above item by item.