Boost plastics injection moulding efficiency with Netstal’s Smart Operation

In today’s competitive manufacturing landscape medical technology and healthcare, thin-wall packaging and closures industries face the constant challenge of maximising efficiency and minimising downtime. Netstal’s Smart Operation is a solution designed to optimise operating processes in injection moulding production processes across these sectors. By reducing idle times, streamlining operations, and enhancing productivity, Smart Operation empowers manufacturers to maintain high-quality standards while boosting overall production efficiency. This solution is crucial for industries where precision, speed, and reliability are paramount.

Addressing efficiency losses in high-performance production

In fast-paced production environments, efforts are often made to shorten cycle times, aiming to increase output. However, these gains are often eaten up by small efficiency losses. Some downtimes are either not taken into account or are regarded as unavoidable. This applies in particular to waiting times that are due to specific operating processes. For example, when production has to be paused for a routine task and can then only be restarted by specially trained personnel. Smart Operation provides a solution to this challenge, allowing manufacturers to eliminate unnecessary idle times and substantially boost productivity.

Real-world application: Retrofitting with Smart Operation

The impact of Smart Operation can be seen in real-world examples. In one case, a company producing dental components faced regular stoppages in their injection moulding machines to lubricate moulds. The issue arose because the maintenance staff were not trained to operate the moulding machines, requiring an application technician to be summoned each time. This specialist, responsible for multiple systems, often caused delays as the machines awaited their return. These short waiting periods accumulated over time, leading to significant production losses.

Netstal addressed this issue by implementing Smart Operation. By integrating specific production processes into the machine’s control system, a guided operation was developed, enabling maintenance personnel to perform the tasks without errors after minimal training. This upgrade led to a substantial increase in productivity, with the company reporting a six-figure boost in turnover due to the elimination of frequent, short idle times. Now, maintenance staff can independently stop production, perform the necessary tasks, and seamlessly resume operations, including the functioning of removal robots and packaging systems.

Enhancing usability with intuitive and safe operation

The Smart Operation system is built around simplifying the operator’s interaction with the machinery. It does this by embedding operation-relevant scenarios and processes directly into the control system, allowing status changes with a simple button press. The system offers four “Smart Buttons,” each with a specific function and a color-coded interface that clearly indicates available options. For example, a red button might indicate “Stop cycle mode,” while green would signify “Start cycle mode.” If additional steps are required—such as ejecting the injection unit—these instructions are displayed on-screen and must be confirmed before proceeding. This user-friendly approach is as intuitive as operating a coffee machine that signals when maintenance, like emptying grounds or running a descaling program, is needed.

Another significant advantage is seen during night shifts, where Smart Operation enables immediate fault rectification by on-duty personnel, eliminating the need to wait for an application engineer. This capability minimises downtime and maintains consistent production flow.

Maximising overall production efficiency

Netstal’s Smart Operation offers a multitude of advantages, providing users with a wide range of benefits that enhance efficiency, productivity, and overall performance. By implementing clearly defined processes, the system protects equipment from improper use, reduces the risk of operating errors, and lowers repair costs. The increased system availability directly translates to higher efficiency. Moreover, the intuitive design minimises the need for extensive training, and the elimination of paper-based instructions further streamlines operations.

This advanced feature can be retrofitted to all Netstal machines equipped with control system generation Axos 7, enabling significant improvements even on existing machinery.

Are you looking to upgrade or retrofit your injection moulding machines?

For more information on how Netstal’s Smart Operation can optimise your injection moulding processes and enhance your production efficiency, contact our injection moulding experts. We’re here to provide detailed insights, offer tailored solutions, and help you take your manufacturing operations to the next level.