IoTFlows Docs

Overview

Injection molding machines are ideal candidates for IoTFlows monitoring using the Continuous Analysis algorithm. This tutorial walks you through setup, configuration, and optimization for perfect production tracking with minimal manual intervention.

What you'll learn:

Why Continuous algorithm is perfect for injection molding
How to configure cycle time and downtime filter
Best practices for multi-cavity molds
Troubleshooting common issues

Time required: 30-45 minutes for complete setup

Why Continuous Algorithm for Injection Molding?

Injection molding machines have consistent, predictable cycle times with brief pauses between shots. The Continuous algorithm is purpose-built for this scenario:

✅ Known cycle times: Each shot takes a predictable amount of time

✅ Brief pauses: Small delays between cycles (mold open/close, part ejection) should be ignored

✅ High volume: Hundreds or thousands of shots per day

✅ Consistent operation: Once running, molding machines maintain steady rhythm

Step-by-Step Setup

Step 1: Install and Calibrate SenseAi

Mount SenseAi on the machine

Attach the SenseAi sensor to a metal surface close to the injection unit or hydraulic pump. Avoid mounting on panels that dampen vibration.

Power and connect

Connect USB-C power and pair the device to WiFi using the IoTFlows mobile app.

Verify detection

Run the machine through several cycles and confirm SenseAi is detecting activity in the Devices Tab.

See the full SenseAi Installation Guide for detailed instructions.

Step 2: Measure Your Actual Cycle Time

Before configuring the Parts List, you need to know your actual cycle time.

Run the machine normally

Start production and let the machine run 10-20 complete cycles

Time the cycles

Use a stopwatch to measure the time from shot start to shot start. Record 10 measurements.

Calculate average

Average your measurements. For example:

Cycle 1: 22 sec
Cycle 2: 21 sec
Cycle 3: 23 sec
... (continue for 10 cycles)
Average: 22 seconds

Note brief pauses

Observe typical pauses between cycles (usually 1-5 seconds). You'll account for these with the downtime filter.

For multi-cavity molds, measure the time per shot (not per part). You'll use Quantity Per Cycle to account for multiple cavities.

Step 3: Create the Operation in Parts List

Navigate to Parts List

Go to Production Tab → Parts List

Click Add Part

Click + Add Part in the top-right corner

Fill in operation details

Operation Name: e.g., "MOLD-WIDGET-A"
Part/Material: e.g., "Plastic Widget"
Description: e.g., "4-cavity mold producing plastic widgets"

Select Continuous Analysis algorithm

From the Algorithm dropdown, choose Continuous Analysis

Enter cycle time

Input the average cycle time you measured (e.g., 00:00:22 for 22 seconds)

Set Quantity Per Cycle (if multi-cavity)

Single cavity mold: Set to 1
2-cavity mold: Set to 2
4-cavity mold: Set to 4
8-cavity mold: Set to 8

Example: A 4-cavity mold running 100 cycles produces 400 parts total.

Save the operation

Click Save or Add Operation

Step 4: Configure Downtime Filter

The Downtime Filter eliminates noise from brief pauses between cycles.

Recommended setting: 200%

Edit the operation

In Parts List, click the edit icon for your injection molding operation

Set Downtime Filter to 200%

In the Downtime Filter field, enter 200%

Understand what this does

With a 22-second cycle time and 200% filter:

Any downtime under 44 seconds (22 × 2) is converted to uptime
Only stops ≥44 seconds are recorded as downtime

This eliminates brief pauses (mold open/close, part removal, quality checks) while capturing real stoppages.

Save changes

Click Save

Why 200%? Typical pauses in injection molding are 1-5 seconds. Setting the filter to 200% (2× cycle time) ensures these brief pauses are ignored while capturing real downtime events like material shortages, mold issues, or operator intervention.

Step 5: Assign Operation to Machine

Go to Assets Tab

Navigate to Assets Tab → Overview

Click on your injection molding machine

Open the machine detail view

Click Auto-Detect

Find and click the Auto-Detect button

Select your operation

Choose the injection molding operation you just created (e.g., "MOLD-WIDGET-A")

Confirm selection

The machine will now track production using Continuous algorithm with your configured cycle time and downtime filter

Step 6: Validate and Monitor

Run for 1-2 hours

Let the machine run normally for at least 1-2 hours

Check production count

Go to Production Tab → Shift Production and verify the part count makes sense.

Validation:

Runtime: 60 minutes = 3,600 seconds
Cycle time: 22 seconds
Expected parts (single cavity): 3,600 ÷ 22 ≈ 163 parts
Expected parts (4-cavity): 163 × 4 = 652 parts

Your actual count should be close to this (±5-10%).

Review downtime events

Check Assets Tab → Downtimes to ensure only meaningful stops are captured (not brief pauses)

Adjust if needed

Count too high: Increase downtime filter (try 250% or 300%)
Count too low: Decrease downtime filter (try 150%)
Count way off: Verify cycle time is correct

Common Issues & Solutions

Best Practices for Injection Molding

1. Use Consistent Mold Configurations

If you run the same part in molds with different cavity counts:

Create separate operations for each mold configuration
Example: "WIDGET-2CAV" and "WIDGET-4CAV"
Use Auto-Detect to switch between them

2. Account for Color/Material Changes

Material or color changeovers can take 15-30 minutes:

Train operators to classify this as "Material Change" downtime
Create auto-classification rule if changeovers are frequent

3. Set Realistic OEE Goals

Injection molding typically achieves:

Manual operations (loading inserts, etc.): 60-75% OEE
Fully automated (no manual intervention): 75-85% OEE
Lights-out (24/7 automation): 85-90% OEE

Start with a goal 5-10% above your current baseline.

4. Monitor Scrap/Reject Rate

If your injection molding process has quality sensors:

Track bad parts separately
Use this data to calculate true OEE (accounting for quality losses)

5. Use Shift Production for Real-Time Goals

During each shift:

Display Shift Production page on a TV
Operators can see if they're on track to meet daily goals
Intervene proactively if falling behind

Real-World Example

Company: Precision Plastics Inc. Machine: 200-ton injection molding machine Part: 4-cavity mold producing automotive clips Cycle time: 18 seconds Cavities: 4 parts per shot

Configuration:

Algorithm: Continuous Analysis
Cycle Time: 00:00:18
Quantity Per Cycle: 4
Downtime Filter: 250% (filters downtimes under 45 seconds)

Results:

Before IoTFlows: Unknown utilization, frequent material shortages
After 1 month: 68% utilization identified
After 3 months: 78% utilization achieved by reducing material shortage downtime
ROI: 15% production increase = $45K annual value

Next Steps

Monitor in Real-Time

View live machine status in Assets Tab

Track Production Goals

Monitor shift production progress

Analyze Downtime

Identify improvement opportunities

Have questions about injection molding monitoring? Contact support@iotflows.com or share your setup in the feedback!

Tutorial: Injection Molding Machines