Where Margins Are Made
In metal and plastics processing, material costs are 50-70% of your total cost. Every defective part is money in the scrap bin. Every second of cycle time drift is capacity you'll never recover. Small improvements in yield and efficiency translate directly to the bottom line—but you can't improve what you can't measure.
The Process Manufacturing Challenge
Hidden losses that erode your margins
Scrap Eats Margins
Material costs are your biggest expense. Every defective part is money thrown away. Small yield improvements create significant profit impact.
Die/Mold Mysteries
Which die is causing defects? When does a mold need maintenance? Without data, you're guessing until it fails catastrophically.
Cycle Time Drift
Machines slow down gradually. Operators don't notice 0.5 seconds per cycle—but over a shift, that's real capacity loss.
How DigiWin Solves It
Data-driven visibility for process manufacturing
Process Parameter Monitoring
Capture temperature, pressure, speed from every cycle. Correlate parameters to quality outcomes.
Die/Mold Management
Track shot counts, maintenance history, and performance by tool. Predict maintenance needs before failures.
Scrap Analysis
Categorize defects by type, correlate to machine, shift, material lot. Find root causes, not just symptoms.
Cycle Time Optimization
Real-time cycle time monitoring against standards. Alert on drift and identify bottlenecks.
BOI Compliance
Production-order-level material reconciliation for BOI audits. Track actual material consumption per mold run — essential for co-product and multi-cavity tracking.
Why Metal & Plastics Manufacturing Needs Specialized ERP
7 production realities that generic ERP systems simply cannot handle
Dual Unit Conversion
Track inventory in both KG (raw material) and PCS (finished parts) simultaneously — automatic conversion at every transaction.
Heat Treatment Outsourcing
Manage external processing workflows where parts leave and return — full traceability through the outsourcing cycle.
Furnace & Batch Tracking
Monitor furnace parameters (temperature, duration, atmosphere) tied to specific batches for quality certification.
Die & Mold Management
Track die/mold lifecycle — usage counts, maintenance schedules, cost allocation across products.
Container Quantity Control
Manage standard container quantities for efficient warehouse operations and accurate shipping.
Multi-Process Routing
Handle complex routing where parts go through stamping, deburring, plating, and assembly with different cost centers.
Scrap & Yield Management
Track material yield rates per operation, auto-calculate scrap costs, and feed back into BOM costing.
Process Types We Support
Recommended Products for Metal & Plastics
AIoT
Machine connectivity for presses, injection molders, and CNC machines. Real-time OEE and process parameter capture.
Learn More →MES
Production tracking, quality data collection, scrap analysis, and die/mold management for process manufacturing.
Learn More →iGP ERP
Right-sized ERP for metal and plastics operations with strong inventory and costing capabilities.
Learn More →Improve Yield, Reduce Scrap
See how DigiWin helps process manufacturers