November 23, 2023

6 min read

Transforming Manufacturing Operations: The Role of Industrial IoT in Optimizing Tool Maintenance

Last November 8, MATIX participated in the annual Conference of Plastic Manufacturing in Milan. Our CEO, Riccardo Pistorello, had the pleasure of taking the stage to present technological innovations in the field of tooling maintenance and management.

During his talk, Riccardo analyzed in detail the emerging trends in the field of plastic processing automation, focusing on how these can be integrated to streamline the maintenance and management of production tools. Finally, starting by highlighting common challenges in the plastics industry, he proposed innovative technologies such as MATIX, which aims at increasing productivity and reliability in manufacturing processes.

In the intricate landscape of manufacturing, molds and dies stand as pivotal assets, exerting a direct (tool fabrication cost) and indirect (breakdowns, downtimes etc.) impact on the effective costs of any fabricated product. The adoption of Industrial Internet of Things (IIoT) emerges as a transformative solution, promising substantial savings and operational enhancements.

Maximizing Value Across the Manufacturing Spectrum with Smart Tools

In the era of Industry 4.0, the integration of smart tools becomes a pivotal factor in optimizing the entire manufacturing value chain. Original Equipment Manufacturers (OEMs) are recognizing the potential of electronic monitoring by incorporating it into tool specifications from the outset. By actively monitoring assets at the molder, OEMs not only ensure efficient tool utilization but also pave the way for enhanced visibility throughout the production process.

Molders, on the other hand, can leverage electronic monitoring to showcase value-added services to OEM customers, offering a transparent view of tool performance while simultaneously gathering crucial operational data. For Mold Builders, the incorporation of electronic monitors into tool specifications provides unparalleled insight into how molds are utilized and maintained, enabling proactive measures for improved efficiency and longevity.

This collaborative embrace of smart tools across the value chain not only fosters transparency but also establishes a foundation for data-driven decision-making, ultimately propelling the manufacturing sector into a new era of efficiency and innovation.

The Strategic Significance of Molds and Dies

Molds and dies are the unsung heroes of manufacturing, shaping the quality and efficiency of the end product. Traditional maintenance approaches often fall short, proving to be both costly and ineffective. This is where the infusion of Industrial IoT technologies revolutionizes the landscape, reshaping the way we approach mold and die maintenance.

The Power of Data: Unveiling the Impact

The data landscape underscores the urgency of embracing innovative solutions. Molds and dies not only contribute to 60% of production costs but also can play a pivotal role in reducing the frequency of unplanned failures by an impressive 20%. This translates to fewer disruptions, heightened productivity, and, ultimately, a substantial competitive edge for manufacturing enterprises.

Cutting Maintenance Management Costs: A Strategic Imperative

A crucial facet of Industrial IoT is its ability to cut down on maintenance management costs. Through the implementation of smart sensors and advanced monitoring systems, maintenance can be conducted preventively rather than reactively. This results in a noteworthy 40% decrease in maintenance management costs, enabling companies to allocate resources more efficiently and strategically.

Mitigating Unplanned Repair Costs: A Financial Advantage

Unplanned repairs can entail unforeseen expenses and production delays, posing significant challenges to manufacturers. Industrial IoT intervenes in this context, reducing unplanned repair costs by up to 25%. This not only has a profound impact on a company's bottom line but also allows for the proactive planning of maintenance activities, avoiding costly emergencies.

Practical Implementation of Industrial IoT: Realizing the Potential

The adoption of Industrial IoT is no longer a choice but a necessity for manufacturing enterprises aiming to stay competitive in an ever-evolving industry. Introducing intelligent sensors on molds and dies enables continuous data collection, providing valuable insights into their status and performance. Real-time analysis of this data allows for predictive maintenance, optimizing overall efficiency and ensuring a smoother production process.

The Future of Manufacturing: Embracing IIoT for Long-term Success

In conclusion, embracing Industrial IoT solutions for mold and die maintenance like MATIX is not merely a strategic decision; it is a transformative journey that yields significant advantages. The numbers are compelling:

  • a 20% reduction in failure frequency;
  • a 40% cut in maintenance management costs;
  • a 25% decrease in unplanned repair costs.

Industrial IoT is not just an investment in the present but a guarantee for a more efficient and competitive future in the realm of industrial manufacturing. As the industry continues to evolve, those who harness the power of IIoT will undoubtedly lead the way towards a more streamlined, cost-effective, and sustainable manufacturing landscape, ensuring long-term success in a dynamic and competitive market.

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