Shotscope Process Monitoring System - Enhancing Injection Molding Efficiency

1. Shotscope Advanced Production and Process Control Overview

2. Table of Contents • Shotscope Introduction • System Architecture Overview • Shotscope Modules • Summary

3. SHOTSCOPEProcess Monitoring Shotscope – An Integral Part of Moldflow’s Value Chain DASGroup MMSGroup

4. Control your Processes with Shotscope • Moldflow’s Shotscope process monitoring system provides a wealth of “at a glance” information to help you control your injection molding processes, improve productivity and minimize scrap and downtime. • Shotscope measures key process parameters and helps manufacturers manage their plant better because… “What can’t be measured, cannot be managed”

5. Solve Factory Floor Problems with Shotscope • Shotscope addresses key manufacturing issues such as: • Little or no real-time information flow for... • Process management (SPC & SQC) and reporting • Job scheduling • Scrap tracking • Difficult to document part manufacturing history (traceability) • Poor integration to enterprise-wide management systems (ERP, MRP) • …and many more!

6. The Shotscope Product Family • Shotscope • Comprehensive, plant-wide process monitoring system that helps manage high-volume manufacturing • Link between shop floor and front office • Shotscope FX • Single machine configuration, expandable to plant-wide solution • Move PC from machine to machine or connect it permanently to machine running a critical job • Available for injection molders and die casters

7. Beginning Shotscope Capabilities at a Glance • Shotscopeis a critical quality analysis technology designed specifically to prevent defective parts from entering the supply chain. • Automatically stores processing parameters on every shot from every machine in real-time • Monitors screw position, velocity, pressures, temperatures… • Displays real-time status of every job • Archives collected data • Creates intuitive shot profile graphs • Protects key information by limiting unauthorized access • Makes all information available across the network • Utilizes Moldflow Plastics Expert (MPX) data for set-up optimization (DOE)

8. Key Shotscope Capabilities • Collect complete data on every shot from every machine • Collect up to 2000 data points on every shot • Store up to 50 process parameters for each machine on every shot • Display real-time status of every job “Real-time Process Monitoring and Analysis”

9. Key Shotscope Capabilities • Activate alarms and part diverters when process limits are violated • View interactive run charts • Display histograms, X-bar and R control charts, and scatter diagrams • Process capability automatically calculated & displayed • Calculate process parameter specification limits “The intelligent SPC Tool”

10. Pareto chart of downtime causes Images/text per job to expedite setup Key Shotscope Capabilities • Report real-time status on every job on every machine • Create standard reports that summarize performance by job, machine, mold, and part number • Graphically display scrap and downtime causes • Customize reports based on shifts, days, weeks, months or years “Flexible Production Reporting”

11. Table of Contents • Shotscope Introduction • System Architecture Overview • Shotscope Modules • Summary

12. How does Shotscope work? • Collects data from machine using A9800 Machine Interface Unit (MIU) • Displays results of latest cycle on the touch-screen computer • Collects and stores data on the database • Makes information available anywhere on the network on Shotscope clients

13. 4/8/16 ports Touch screen Plant-wide Configuration

14. A9800 Workstation Single Machine Configuration – Shotscope FX Portable Analyzer • The Shotscope FX portable version can be moved from machine to machine for set-up, troubleshooting, machine capability studies, and part quality checks. • Shotscope FX can be expanded easily into a plant-wide monitoring solution as necessary.

15. Table of Contents • Shotscope Introduction • System Architecture Overview • Shotscope Modules • Summary

16. Shotscope Client Software Modules Standard Modules (Shotscope Base) • Real-time Monitoring • Shot Profile Analyzer Optional Modules • Statistical Process Control (SPC) • Statistical Quality Control (SQC) • links part quality (weight/dimension) to process parameters through direct interface with measurement devices and/or scatter diagrams (linear regression) • Job Scheduling • Production Reporting • Preventative Maintenance (PM)

17. Operator Interface • Easy to use shop floor interface • Touch screen interface • Simple data input • Login, scrap, downtime • Report screens available • SPC • Shot Profiles • HTML Document Viewing

18. Factory Floor Monitoring • Real-time feedback of machine conditions • green - in tolerance • yellow - out of tolerance • red - machine down • User-configured machine layout

19. Process Parameters • Process parameter updates in real-time • User-selectable viewing • Indicates whether parameters are in/out of tolerance

20. Document Viewer • HTML Document Viewer • Process setup sheets • Part defect examples • Machine schematics • Material spec sheets • Tooling diagrams

21. Shot Profile Analyzer • Displays 8 dynamic signals • screw position • hydraulic pressure • cavity pressure • etc. • Overlay profiles • Recall any profile • Store any profile

22. SPC Analyzer • Different types of charts • Run charts • X-bar & R control charts • Histograms • Scatter (linear regression) • Value of any parameter with a simple mouse click • Shot number, date and time stamp included • Add notes to run charts • Display point where material lot number changed

23. SQC Entry • Correlate part dimensions with process parameters • Interface with digital tools such as: • micrometers • calipers • scales • Alerts user to dimensions out of specification

24. Job Scheduler • Simple drag-and-drop scheduling • Real-time updates for job completion based on • Actual cycle times • Scrap rates • Cavitation • Downtime • Supports family molds • Alerts user to late jobs

25. Production Reporting • Various report categories • Scrap • Downtime • Efficiencies • Several chart styles • Pie Charts • Pareto Charts • Tabular

26. Preventative Maintenance (PM) Module • Tool Maintenance • tracks number of shots per tool • Machine Maintenance • tracks operating hours per machine • Alerts user when maintenance is due • Maintenance Database • Tools used in maintenance • Replacement components used in maintenance

27. Table of Contents • Shotscope Introduction • System Architecture Overview • Shotscope Modules • Summary

28. Shotscope Summary • Cutting-edge process monitoring and analysis system • Comprehensive product suite • Shotscope – Plant-wide configuration • Shotscope FX – Single-machine configuration • Collects critical data in real time from injection molding machines on the factory floor • Records, analyzes, and reports • Allows access to the information for use in critical decision making

29. Shotscope Benefits at a Glance • Establishes process control • Improves process stability • Maintains or improves current process control • Decrease cycle times • Improve quality and lower scrap • Reduce machine downtime • Simplifies reporting and expedites information flow • Increases plant utilization • Simplifies plant scheduling • Increase percentage of on-time deliveries • Document ISO 9000 conformance • Link process/production data to ERP systems

30. Thank You Beginning