MITSUBISHI ELECTRIC Veranderingen ten goede

Preventing defect outflow

Stopping quality issues before they escalate

Imagine you have a problem with preventing defects outflow during the moulding of a component. You already have known that even the smallest defect in resin moulding – whether it’s an air bubble, a dent, or a surface flaws – can compromise product quality and lead to costly rework or waste. Moreover, these defects often go unnoticed in the early stages of production, gradually accumulating and making their way further down the supply chain. Since the root causes of such defects aren’t always well understood, continuous production issues can arise without immediate detection.
To prevent this outflow of defective products, manufacturers need a proactive approach – one that goes beyond traditional inspections and enables early fault detection. This is where predictive maintenance makes the difference, providing real-time insights to identify potential issues before they affect quality.

A proactive approach to quality control

To effectively prevent the outflow of defects, manufacturers need more than just traditional inspections – they need real-time data analysis that identifies problems before they escalate.  

The process consists of two phases – offline analytics and real-time diagnostics. First, key parameters are extracted and analysed to determine their impact on moulding quality. Then, using diagnostic methods such as Mahalanobis distance and threshold-based evaluation, the system detects early signs of defects and establishes predictive diagnostic rules.

The second step

In the second phase, real-time data collection from the injectors is the basis for detecting signs of faults using predefined diagnostic rules. By using iQ Edgecross (data analysis and diagnostics software) on the MELIPC industrial-use computer, machine performance can be continuously monitored for fault-related patterns.

The equipment operator is alerted when the value of a parameter exceeds a threshold set by a diagnostic rule. This enables manufacturers to take action before multiple faults occur.

  • Real-time collection of injection molder data
  • Detect signs of defects using diagnosis rules 
  • Notify operator when a value exceeds the determined threshold set by diagnosis rules

Preventive maintenance ensures consistent product quality. It is equally effective in preventing defective products from reaching the next production stage. The measurable result is a reduction in waste by detecting signs of moulding defects.

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