Injection Molding Shop Floor Software
An Easy to Use and Affordable Solution
Rockware® Injection Molding solutions offer essential data such as cycles, downtime, and scrap, along with advanced integrated features including process data sheets, process monitoring with SPC, material inventory with traceability, maintenance modules, quality control checks, and multiple scheduling options. These features ensure precise control and optimization of the injection molding process, leading to improved quality, efficiency, and productivity. One of the challenges with injection molding is connecting to proprietary machine controllers. To address this, we offer five different methods to ensure all machines can be connected. Many of our solutions involve connecting to water flow sensors, interlocking the machine, or controlling and monitoring conveyors and other auxiliary devices. Our first injection molding system was launched in 2007 and the platform has been steadily enhanced over the last decade and a half, reflecting our commitment to continuous improvement and innovation.
Seamless Integration
5 Ways to Integrate
Rockbox® iBox™The iBox™ connects to multiple machines featuring isolated relays for connecting to machine outputs and a PLC for managing cycle counters. These boxes come in 4 sizes and consist of industrial components that are reliable and familiar to work on for maintenance and engineering personnel.
Rockbox® RIO™Remote IO modules can be installed on each machine for using discrete inputs for cycle collection, discrete outputs for machine control, and RFID scanners for mold recognition.
Rockbox® DIO™Mini-PLCs can be installed directly in the machine's electrical cabinet using discrete inputs for cycle collection and discrete outputs for machine control.
Rockbox® eDart-X™Middleware software application that facilitates two-way communication with eDarts and can be used to polulate a Rockware® system.
OPC Compliant ControllerThis method allows us to pull all available metrics from machines with full read and write access and requires no additional hardware.
Solutions Isometric Art
Innovative Software
Flexible and Tailored to you
Real-time Traceability
Cycle Time and Cycle Data
Every cycle is logged with a timestamp in our system and tied to applicable machine, tool, shift, and other relevant metrics. Cycle times are derived using cycle time stamps. Cycle data is the basis for all KPI calculations such as OEE. Downtime is calculated by detecting the absence of cycles.
Dashboards and Displays
Dashboards and displays allow you to visualize your plant's performance at one glance. Dashboards and displays can be viewed on any PC, TV, Tablet, or Phone. Dashboards can focus on a plant, a department, or a single machine in a variety of formats.
Granularity by Cavity
Machine cycles tie to applicable tool and cavities to derive parts created and material used. Scrap can be entered based on cavity and zone of part to provide engineers with viable detail for troubleshooting reoccuring issues.
Operator Interfaces
Multiple HMI options for user interaction are available. Interfaces offer scrap entry, downtime code selection, call initiating and answering, first piece verification, quality alerts, video display, work instructions, and more.
Cycle-based preventative maintenance modules for tools and machine-hour based preventative maintenance modules for machines are included with the standard package. Integrated work order modules, call modules, and maintenance dashboards for day to day visual management of maintenance are also available.
Legacy System Conversion
Vendor legacy systems can be converted to a Rockware® system while keeping certain standards such as color scheme and standard reports in-tact.
Shift Recap
This module allows supervisors to reconcile production, downtime codes, and scrap. It also allows users to enter comments and concerns before generating a shift recap report used in team meetings. This is the heartbeat of any molding department.
This module handles the scheduling of customer orders or internal WIP while also tracking all changeovers. Displayed in a GANTT chart, upcoming changeovers can be quickly identified so that resources are allocated in a timely manner.
Material Management
When jobs, cavities, parts, and BOMs are configured properly in conjunction with a schedule, accurate material needs and usage can be tracked and reported.
Process Parameters
Storing process recipes and the monitoring of actual versus standard for cycle time, fill time, cushion, and recovery time are valuable tools for engineers. Trending and SPC tools are available for quick visual analysis
Notifications and Reports
Automated messages and reports can be subscribed to and received via eMsg™ web application, email, or text message.
Resin Traceability
Resin and material handling traceability systems can be integrated with a Rockware® system to prevent mistakes and log material lot numbers to each cycle.