Industry one-pager

Plastics — injection and blow moulding

Four cavities are blocked. Your price list still assumes eight.

What it costs you today

01
The mould has run at four of its eight cavities since March. The routing still says eight.
Output per hour halves, the duration on every order doubles, and the machine cost per part doubles with it. Meanwhile the quotation, the schedule and the margin report all still use the design specification. The loss is real, continuous, and nowhere on a report.
02
Preventive maintenance is due every 50,000 shots and you find out you passed it when the parts start failing.
A mould has an expected life measured in shots, not months. Miss the service interval and you are not scheduling maintenance, you are scheduling a repair — and a repair is downtime on the machine as well as cost on the tool.
03
The recipe says 70% virgin, 28% regrind, 2% masterbatch. Nobody stops the operator who runs it at 45% regrind on a food-grade part.
Regrind is free material until the day it is a customer complaint, a failed batch or a lost food-safety approval. The ceiling has to be a hard block in the system, not a note on the wall.

Cavity-aware capacity and cost
Each mould carries its cavity count and the status of every cavity. Output per hour is computed from the cavities actually running and the cycle time, so a blocked cavity changes the schedule and the unit cost the moment it is recorded — and a running total shows what the blockage has cost this month.
Maintenance measured in shots
Shot counters per mould, service intervals in shots, expected life in shots, and an alert before the interval rather than after it. Repair decisions get a payback figure: cost of the repair against the daily cost of running the tool damaged.
Percentage recipes that resolve to kilograms
You write the formulation the way the plant thinks about it — virgin, regrind, colorant, additive as percentages — and the system produces the bill of material in kilograms for the batch size being run. Regrind ceilings are enforced per product, and a food-grade part cannot be released above its limit.
Batch genealogy, both directions
Resin lot into the order, order into the scrap, scrap into the regrind lot, regrind lot into the next order. Forward from a resin lot to every part it touched, and backward from a complaint to every lot involved — in the time it takes to open a record, which is what an audit or a recall actually requires.

Thirty minutes on the phone. We tell you whether we can help and roughly what it takes — before anyone talks about scope or price.