Plastics & Packaging
Injection, blow and extrusion units where resin price, mould changeovers and regrind decide the month.
A moulding plant runs on three numbers: kilograms of polymer in, good pieces out and the hours a mould sits on a machine. Foundepth measures all three on the same job card, so the cost of a 20 litre container is calculated from what the shop floor actually did.
What pushes on this building.
Resin moves every fortnight
Polymer rates shift with crude and import parity. A quote built on last month's rate can lose the margin before the first batch.
Changeovers eat capacity
Every mould change costs one to three hours. Running orders in the wrong sequence quietly removes a shift each week.
Regrind is invisible stock
Runners, flash and rejects are ground and reused, but rarely counted. Yield looks better or worse than it really is.
Weight per piece drifts
A container that should weigh 820 g and runs at 845 g adds 3% to material cost on every piece, and nobody sees it until the stock count.
One order, floor by floor.
How a common order moves through Foundepth in a moulding plant.
- 3Step 1 · Order Desk
Order for 1,200 pcs of 20 L HDPE container, 820 g each, despatch on the 18th.
- 2Step 2 · Shop Floor
Work order explodes the BOM: 984 kg HDPE, 12 kg masterbatch, 1,200 caps.
- 1Step 3 · Buy Desk
Shortage of 40 kg HDPE raises a purchase request with the job card attached.
- GStep 4 · Stock Room
Resin received by batch, reserved against the job card at the rack.
- 2Step 5 · Shop Floor
Job card records shots, good pieces, rejects and kilograms sent to regrind.
- BStep 6 · Ledger Core
Consumption, WIP and finished goods value post to the ledger the same day.
Controls that ship with it.
Configured on day one of implementation, not built as custom work later.
- Standard weight per piece on the item, with variance flagged per batch
- Mould master with cavities, cycle time and the machines it fits
- Regrind as its own stock item, returned at a set percentage
- Masterbatch and additive dosing held on the BOM by percentage
- Machine wise output and downtime with reason codes
- Polymer rate history by grade and supplier
Reports this site reads every week.
- Yield by machine and mould
- Material cost per piece, actual vs standard
- Changeover hours per week
- Resin cover in days
Running order 2284 before 2290 on machine 3 saves two mould changeovers this week.
Recommendation only. A person decides.Other site types.
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