Run Your Injection Moulding Factory With Live Production Visibility and Better Control
Plan production from stock levels, know material shortages before they stop a machine, control FIFO, track mould life and maintenance, and turn rejection and downtime into management-visible losses — from one manufacturing ERP.
Machines Running
9 / 12
Behind Plan
3
Downtime Today
96 min
WC-01 · 120T
On PlanLever 8553
WC-04 · 150T
Behind PlanHousing LH
WC-07 · 250T
WatchBracket RH
Mould Alert
MLD-0045 · 98.5% tool life used
Dispatch Risk
Housing LH · FG below safety stock
Illustrative dashboard · sample data
See Where Machine Capacity Is Being Lost
OEE helps injection moulding factories improve machine utilization by identifying losses from downtime, slow cycles and rejection — leading to higher good output from the same machines. The purpose is not to show another percentage. The purpose is to show management where available production time is being lost and what needs attention.
- See machine / workcenter runtime against available production time.
- Expose downtime by machine, reason and duration instead of relying on end-of-shift explanations.
- Compare planned vs actual output and identify machines running behind plan.
- Make rejection visible as lost productive capacity, not only as a quality percentage.
- Review daily, weekly and monthly machine performance to identify repeated capacity losses.
- Support decisions on maintenance, cycle-time improvement, manpower — or whether another machine is truly required.
WC-04 | 150T Injection Moulding
Product: Housing LH · Shift A
Plan
4,500
Produced
3,860
Rejection
96
Downtime
42 min
Where the time went
Owner / Plant Head
“Before investing in another machine, show me how much of the capacity I already own is actually becoming good production.”
Production Manager
“Which machine is behind plan, how much time was lost, and is the loss from downtime, slower cycle or rejection?”
IndiAps ERP Nxt has been successfully implemented for manufacturing companies in and around Chennai. We work with factory teams to understand the actual process and bring production, inventory, quality, maintenance and traceability into one connected system.
Chennai & surrounding manufacturing belt
Stop Planning Production From Memory, Calls and Spreadsheets
Production planning based on Min, Re-order and Max stock levels automatically prioritizes what to produce and how much — helping prevent shortages, reduce overproduction, maintain optimum inventory and improve on-time dispatch.
- Start with the complete month / dispatch requirement and calculate the per-day finished-goods need.
- Bring in current FG stock, WIP stock, Work Order pending quantity and Work Order quantity still to be created.
- Compare the stock position with Safety Stock, Minimum Stock, Re-order Level and Maximum Stock.
- Below Safety looks urgent, below Min looks actionable, below Re-order shows as upcoming need — and stock near Max discourages unnecessary production.
- Consider product delivery priority and workcenter capacity when converting suggested quantity into the daily plan.
- Show the expected stock position after production, so planners see the consequence of a decision before releasing work.
Product: Housing LH
Stock-level position · WC-04
FG Stock
1,200
Safety
1,500
Min
2,500
Re-order
3,500
Max
5,000
Req / Day
600
WIP
400
WO Pending
800
Expected stock after production
3,800above Re-order
Management
“Are we producing what the customer needs, or simply what is convenient to run?”
Planning
“If I approve this quantity today, where will FG stock stand after production and what product becomes the next priority?”
Daily production plan
Sample data| Product | Cycle / Cav | Safety | Min | Re-order | Max | Req/Day | FG | WIP | WO Pend | WO TBC | Planned Qty | Exp. Stock | WC | Status |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Housing LH | 38s / 4 | 1,500 | 2,500 | 3,500 | 5,000 | 600 | 1,200 | 400 | 800 | 1,400 | 2,600 | 3,800 | WC-04 | Priority Production |
| Lever 8553 | 22s / 8 | 2,000 | 3,000 | 4,200 | 6,000 | 900 | 2,850 | 600 | 400 | 500 | 1,800 | 4,650 | WC-01 | Below Min |
| Bracket RH | 45s / 2 | 800 | 1,400 | 2,000 | 3,200 | 300 | 2,240 | 0 | 600 | 0 | 600 | 2,840 | WC-07 | Replenish |
| Clip Cover | 16s / 16 | 3,000 | 4,500 | 6,000 | 9,000 | 1,200 | 8,400 | 1,200 | 0 | 0 | 0 | 8,400 | WC-02 | Near Max — Hold |
Planned quantity stays editable — planners can adjust against workcenter capacity and delivery priority before releasing work orders.
A production plan is only useful if the material is available. The next step is to know the raw-material requirement before the shortage reaches the shop floor.
Know What Purchase Needs Before Production Asks
MRP calculates raw-material requirements from production or dispatch demand, checks available stock against Min / Re-order / Max levels, combines common RM demand across products, and highlights what needs to be purchased — reducing shortages, excess inventory and last-minute procurement.
- Explode finished-goods demand through BOM to calculate the RM requirement.
- Consolidate the same RM used by multiple finished products instead of purchasing product-by-product.
- Compare required quantity with current company stock and configured stock levels.
- Apply a configurable rejection / process buffer where required.
- Show shortage to Min, Re-order and Max so Purchase can separate urgent need from replenishment opportunity.
- Make the source of demand visible: which finished products are creating the RM requirement.
RM: PA66 GF30
Consolidated requirement · this week
Current Stock
420 kg
Requirement
690 kg
Buffer
3%
Min
500
Re-order
800
Max
1,200
Immediate purchase requirement
291 kgdemand + buffer
Demand from
Older Batches Move First — Because the System Says So
FIFO for raw materials and finished goods ensures older batches are consumed or dispatched first — reducing ageing stock, avoiding expiry or quality issues, improving batch traceability and keeping inventory rotation under control.
Raw Material FIFO
At material issue, Stores is guided to the oldest eligible RM batch. QR / batch validation is part of the issue flow, so a newer batch cannot casually bypass an older batch without a controlled reason.
Finished Goods FIFO
At dispatch, the oldest eligible FG batch is identified first. The dispatch team knows exactly which batch to pick — without manually checking multiple racks or Excel lists.
Batch traceability — the actual factory flow
“If an OEM calls about one supplied batch, can we quickly show which raw-material batch was used, when it was produced, on which work order, and which finished-goods batch was dispatched?”
Protect the Tools That Keep Production Running
Mould life cycle tracking monitors mould usage, stroke count, maintenance due, current status, location and remaining tool life — helping prevent unexpected mould failure, reduce downtime, plan maintenance and improve mould utilization.
- Maintain expected tool life and current usage in strokes.
- Map the mould to product and relevant machine / workcenter information.
- Capture issue to production, in-use status, return and current location.
- Generate maintenance awareness from stroke frequency instead of relying on memory.
- Show remaining tool life and approaching end-of-life risk to Production and Maintenance.
- Keep a maintenance history so recurring mould problems become visible.
Mould: MLD-0045
Product: Bracket LH · Location: WC-04
Expected Life
5,00,000 strokes
Current Usage
4,92,600
Status
In Use
Remaining
7,400 strokes
Schedule mould maintenance before the next work order is released on WC-04.
Preventive Schedules Plus the Breakdowns Production Actually Raises
Machine preventive and on-demand maintenance helps schedule routine service based on time or usage while also capturing breakdown requests as they occur — reducing unplanned downtime, improving machine reliability and maintaining a complete maintenance history.
Preventive Maintenance
Frequency, last maintenance date, next due, machine / workcenter, standard preventive activities and completion history. The system should help Maintenance act before failure.
Breakdown / On-Demand
Production raises the maintenance request when a machine problem occurs. Capture breakdown time, reason, corrective action, parts used, start / completion time and downtime.
Management visibility, on request
Top machines by downtime
Top downtime reasons
Repeat breakdowns by machine
Preventive due / overdue
Downtime linked to production loss and OEE
“Maintenance should not be a register that explains yesterday. It should help the factory prevent tomorrow's stoppage and learn from repeated failures.”
Put a Rupee Value on Quality Loss
COPQ tracks the financial impact of rejections, rework, scrap, customer returns, inspection failures and production losses — helping identify where quality issues are costing the factory most and prioritize corrective action.
- Show internal rejection, rework, scrap and customer rejection / returns separately.
- Where practical, translate loss into material cost, machine-time loss, rework effort and other measurable cost components.
- Allow analysis by product, defect, machine / workcenter, mould, process and customer.
- Use trend and top-loss views so management can attack the biggest recurring loss first.
Do not stop at “Rejection = 2.8%.” Help management answer: what did poor quality cost us this month, where did that cost come from, and what should we fix first?
Cost of Poor Quality
Month to date · all workcenters
Top defect
Short moulding
Top machine
WC-04
Top mould
MLD-0045
Trend
Rising 3 weeks
Cost components are configured from your own material, machine-hour and labour rates.
No Overdue Instrument Should Reach a Measurement
Instrument calibration tracking monitors calibration due dates, calibration history, results, certificates and instrument status — helping prevent the use of overdue instruments, support audit compliance and maintain measurement accuracy across production and quality processes.
- Instrument ID, serial number / asset tag, category and status.
- Last calibration date, frequency, next due date and alert days.
- Due Soon / Due / Overdue visibility at a glance.
- Calibration result, certificate and complete history.
- Make overdue instruments obvious so Quality can prevent uncontrolled use.
Calibration register
Sample data| Instrument | Category | Next Due | Status |
|---|---|---|---|
| INS-018 · Vernier Caliper | Dimensional | 04 Sep 2026 | Overdue |
| INS-042 · Weighing Scale | Mass | 21 Sep 2026 | Due |
| INS-007 · Micrometer | Dimensional | 08 Oct 2026 | Due Soon |
| INS-031 · Thermocouple | Temperature | 16 Dec 2026 | Calibrated |
Eight Control Areas, One Continuous Flow
Each area above solves a real problem on its own. Together they become a single chain from customer demand to dispatch — with traceability running back through every step.
Why IndiAps
A manufacturing-focused cloud ERP with real-time visibility, personalized implementation, one connected system from order to dispatch, and close support while your team settles into it.
Local Trust
Successful manufacturing ERP implementations in and around Chennai — with factory teams, on the actual process, not on a slide deck.
Before You Buy Another ERP, Show Us Where Your Factory Is Losing Control
Tell us whether the problem is machine utilization, production planning, raw-material shortage, FIFO, mould life, downtime, rejection cost, calibration or traceability. We will discuss the actual process and show how it can be controlled in IndiAps ERP Nxt.