ERP for Injection Molding Industry
End-to-End ERP for Plastic Molding, Tooling, Component Manufacturing & OEM Suppliers
Introduction
Injection molding manufacturers handle continuous machine operations, resin planning, mold changes, cycle-time optimization, rejections, quality control, and fast turnaround for OEMs.
AIS Business Corp's Injection Molding ERP helps integrate material → mold → production → quality → maintenance → dispatch → costing into one streamlined system.
Complete Molding Flow
Suitable for:
Powered by SAP Technologies
SAP S/4HANA
Enterprise-grade ERP designed for large injection molding manufacturers and multi-plant plastic processing operations. Supports advanced finance, production planning and scheduling, mold and tool management, bill of materials (BOM), batch and lot traceability, quality management, scrap and regrind tracking, machine and preventive maintenance, capacity planning, supply chain management, and real-time analytics across end-to-end injection molding operations.
SAP Business One
A complete ERP solution for small and medium injection molding businesses, including plastic component manufacturers and OEM suppliers. Covers raw material procurement, production tracking, mold and tool usage, batch management, quality inspection, costing, sales, finance, warehouse operations, and dispatch management with fast deployment and easy scalability.
Cloud ERP (Private, Public Cloud & On-Premise)
Flexible and scalable ERP deployment options tailored for injection molding operations. Choose Private Cloud for dedicated infrastructure and enhanced data security, Public Cloud for cost-effective SaaS deployment with automatic updates, or On-Premise for full control, deeper customization, and seamless integration with molding machines, MES systems, tool room management, IoT sensors, and legacy applications.
Key Challenges in Injection Molding Industry
Unplanned Mold & Machine Scheduling
High dependency on mold changeovers and setup times.
Resin, Masterbatch & Additive Shortages
Material mismatch directly affects production.
Cycle Time Variation & Machine Inefficiency
Even small delays create large production losses.
High Rejection Due to Quality Issues
Shrinkage, flow marks, short shots, burrs, color variation, etc.
Mold Maintenance & Tool Life Tracking
Regular preventive maintenance is critical for quality.
Real-Time Production Monitoring Difficulties
Without ERP, machine data and operator logs are inaccurate.
AIS Injection Molding ERP - Complete End-to-End Solution
Product & Mold Management
- Mold master & mold lifecycle tracking
- Mold preventive maintenance
- Mold changeover planning
- Tool/spare usage and tracking
- Mold cavity & shot count tracking
- Mold history card
Material Planning (MRP)
- Resin, masterbatch, additives, colorant planning
- Material consumption forecast
- Alternates material management
- Material request & approval workflow
- Lot-wise material tracking
Production Planning & Machine Allocation
- Machine-wise scheduling
- Shot-wise planning
- Cycle time calculation
- Setup time tracking
- Multi-cavity production planning
- Shift-wise production forecasting
Shop Floor & Machine Monitoring
- Real-time machine status
- Shot count updates
- Hourly production reports
- Breakdown logging
- Downtime analysis
- Operator-wise productivity tracking
Material Issue & Consumption Tracking
- Resin & additive consumption
- Auto-backflush based on BOM
- WIP tracking by machine & mold
- Scrap & regrind control
Quality Control
- In-process QC (first piece, hourly QC)
- Finished goods QC
- Defect tracking: short shot, sink marks, black spots, warpage
- Statistical Quality Control (SQC)
- Vision-based QC (optional integration)
Maintenance & Tool Room
- Preventive maintenance schedules
- Breakdown maintenance
- Job cards for repair
- Spare parts tracking
- Maintenance cost analysis
- Tool room work order management
Inventory & Warehouse Management
- Raw materials
- WIP
- Finished goods storage
- BIN/rack storage
- Barcode tracking
- Batch/lot traceability
Sales, Dispatch & Documentation
- Order booking
- Customer-specific packaging
- FG allocation
- Delivery challan
- Dispatch planning
- Invoice generation
- Customer portal access
Finance & Costing
- Material + machine hour + labor costing
- Cycle time-based costing
- Overhead cost allocation
- Rejection cost analysis
- Profitability reports
Automation, Approvals & Alerts
Automation
AIS Injection Molding ERP automates:
- Material issue & consumption posting
- Production confirmations
- Quality inspection posting
- Maintenance job completion
- Costing & finance integration
Approvals
Approval workflows for:
- Material requisitions
- Mold release & changeover
- Purchase orders
- Production order release
- Dispatch authorization
Alerts
Real-time alerts for:
- Cycle time deviation
- Excess rejection & scrap
- Mold maintenance due
- Material shortage
- Machine breakdowns
- Production delay risks
AI, Analytics & Intelligent ERP
With SAP-powered analytics, AIS Injection Molding ERP provides:
Predictive machine downtime alerts, Mold life & shot-count forecasting, Cycle time optimization insights, Rejection trend analysis, OEE & productivity improvement recommendations, and Cost leakage identification.
This shifts operations from reactive control to predictive decision-making.
Reports & MIS (Injection Molding ERP)
Inventory & Stock Reports
- Stock Register
- Stock Comparison Report
- Stock Valuation Report
Production & Planning Reports
- Production Order Status Report
- Planned vs Actual Production Quantity
- Machine-wise Production Output
Mold & Machine Performance
- Mold Utilization Report
- Molding Cycle Time Analysis
- Machine Breakdown Report
Quality & Rejection Reports
- Inspection PDI Report
- Rejection / Scrap Percentage Report
Sales & Purchase Reports
- Purchase Register
- Sale Register
- Part-wise Comparison (Month-wise)
- Sales Comparison (Month-wise)
These reports ensure tight control over:
Machines, molds, material, quality, and margins.
Advanced AIS Features
Mobile App Support
- Production entry
- QC checklist
- Tool/mold maintenance updates
- Store inward/outward
- Management dashboards
Integrations Supported
- Machine data integration (IoT/MDC)
- Barcode/QR
- Weighing scale
- Resin dryer/loader sensors
- Tally, SAP, Zoho
Reports & Analytics
- Machine efficiency (OEE)
- Mold performance report
- Shot count & cycle time analysis
- Rejection & scrap reports
- Shift-wise production
- Material consumption vs plan
- Dispatch & delivery performance
- Customer order visibility
Benefits of AIS Injection Molding ERP
Precise machine & mold scheduling
Reduced downtime and faster changeovers
Accurate resin & additive planning
Lower rejection and scrap
Better cycle-time control
Enhanced traceability from material to FG
Real-time production insight for faster decisions
Accurate costing and improved profitability
Seamless customer delivery and packing control
Why Choose AIS Business Corp
Our Implementation Process
Requirement Study (Molds, Machines, Cycles)
BOM & Molding Process Setup
Machine Integration (Optional)
Material, QC & Toolroom Configuration
User Training
Pilot Run & Validation
Go-Live with Monitoring
Frequently Asked Questions (FAQ)
Can the ERP track mold life and shot counts?
Does AIS support machine integration?
Can we manage resin consumption and regrind?
Is preventive maintenance supported?
Can AIS ERP manage mold setups and changeovers?
Does the ERP support cycle time monitoring?
Can it handle multi-cavity mold production?
Is quality inspection supported at every stage?
Can AIS ERP manage tool room operations?
Is batch and lot traceability available?
Call to Action
Digitize your injection molding operations with AIS Business Corp's advanced ERP. Increase efficiency, reduce rejections, and achieve complete traceability. Contact us today for a personalized demo.
Email: cm@ananthinfo.com
