Illustrative scenario
Injection molding shop: machine data and OEE
Know exactly how long each machine stopped and why, instead of handwritten end-of-shift reports.
This is an illustrative scenario with a hypothetical plant, not an Uptrol customer. The figures are estimates from the assumptions listed below, not achieved results.
- Industry
- Plastic injection, parts for electronics and motorcycles
- Assumed size
- 20 presses of several brands, 3 shifts a day
- Scope
- Machine data collection, OEE, shift reports
- Estimated rollout time
- 6–10 weeks
Estimated benefits
1,000–2,000 hoursMachine hours recovered per year
Headline estimate300–600 million VNDValue of recovered machine hours per year
450 hoursReporting hours saved per year
See how we calculated
Assumptions
| Machines monitored | 20 |
| Production days per year | 300 |
| Stop time recovered once causes are known, per machine per day | 10–20 min |
| Value of one machine hour (estimated gross margin) | 300,000 VND |
| Shifts per day | 3 |
| Time to write a manual report per shift | 30 min |
Calculation
- 20 machines × 10–20 min × 300 days ÷ 60 = 1,000–2,000 hours
- 1,000–2,000 hours × 300,000 VND/hour = 300–600 million VND
- 3 shifts × 30 min × 300 days ÷ 60 = 450 hours
Recovered stop time depends on the shop acting on the data; the system makes losses visible.
Context
The hypothetical shop has 20 presses from three brands and different generations; only some have a communication port. Output and stop times are written by hand by shift leaders.
Management sees output below capacity but cannot tell whether the loss is stops, slow running or scrap.
What Uptrol deploys
- Run/stop status and cycle counters from controllers with a communication port
- Older presses: current sensors and stack-light signals via Modbus I/O modules
- A quick stop-reason screen for shift leaders
- Shop dashboard, OEE per shift and part number, automatic shift reports
Architecture
- 01Presses → communication port or added sensors
- 02Shop-floor gateway: read, normalise, buffer during outages
- 03Encrypted outbound connection → Uptrol platform
- 04Dashboards and reports on PC and phone
Steps
- 01Survey and pick data pointsCheck each machine generation, agree on data points and stop reasons.
- 02Pilot on 2 machinesOne with a port, one old; compare with the production log for a week.
- 03Roll out to the shopInstall machine group by group without interrupting production.
- 04Dashboards, OEE, trainingShift reports, stop-reason Pareto; train shift leaders and supervisors.
Related solution: Machine data and OEE