Building scrap registration software for injection moulding
Appfront builds software for die-casting foundries that want to reduce their scrap: rejects recorded at the machine per order, mould and cavity, with the cause, such as short shots, sink marks, flash or burning, alongside the process parameters at that moment, start-up scrap kept separate from scrap during production, and the cost of scrap in material and machine time. So that rising scrap is noticed at once, and you know which mould or product costs the most.
What is scrap recording software for die casting?
In a die-casting foundry, scrap is money that goes to the grinder: material, machine time and energy. Scrap has a cause: a short shot, a sink mark, flash, burning or a dimension that is out of tolerance. That cause often relates to the mould, a cavity, the material or the machine settings. Scrap recording software logs rejects together with the cause and the circumstances, so you can see where it comes from.
In many die-casting foundries, scrap is counted at the end of the shift and noted as a single figure per order. What the cause was, which cavity, and how the machine was set at that moment is not known. Start-up scrap and scrap during production are mixed together. A mould that is slowly wearing and producing more flash is only noticed when a customer complains. And nobody knows exactly what scrap costs per product.
We build custom software because the registration has to fit your production: which machines and controls you have, which moulds and cavities, which causes you distinguish, how your operators work, which MES or ERP holds the orders, and which quality system you use. An MES counts good and defective products; why they are defective, and in which cavity, it often doesn't ask.
Rejects with cause
Scrap recorded at the machine per order, mould and cavity, with a cause code the operator selects in a few taps.
Alongside the process
The machine's process parameters at the moment of scrap, so a link with temperature, pressure or cycle time can be seen.
Costs in view
Scrap converted into material, machine time and money, per product, mould and period.
How we build your scrap recording software for die casting
We start with the scrap from the past month: how much, on which machines and products, and what you currently know about the causes.
Your machines, controllers, moulds and cavities, the causes you distinguish, and your MES, ERP and quality system.
Cause codes per product type, recording at the machine, and start-up scrap kept separate from production scrap.
Counts and process parameters from machine controls where possible, linked to the defect.
Analysis per machine, mould, material and shift, the costs, integrations with MES and ERP, and ongoing maintenance.
What scrap recording software for die casting actually does
The components below come up at almost every die-casting foundry. Which ones you need depends on your machine park and your products.
Recording at the machine
Scrap entered on a terminal or tablet at the machine, per order, mould and cavity.
Cause codes
Short shots, sink marks, flash, burning, dimension, colour and your own codes per product.
Start-up scrap
Scrap during start-up or after a mould change, kept separate from scrap during production.
Process parameters
Temperatures, pressures and cycle time from the machine controller at the moment of scrap.
Analysis
Scrap per machine, mould, cavity, material and shift, with the main causes at the top.
Cost
Scrap converted into material, machine time and cost per product and period.
Who we build scrap-tracking software for in injection moulding
This software is intended for injection moulding companies that currently record scrap as a single figure per shift.
Technical injection moulders
Precision parts with tight tolerances. The cause per cavity and the process parameters are central.
Packaging manufacturers
High volumes with short cycles. Automatic counts and costs matter most.
Automotive suppliers
Strict customer requirements. The analysis and the supporting evidence are what is needed.
Medical plastics production
Products where every deviation matters. Recording by cause and traceability are central.
Test your idea first: a working prototype in 1 day
With OneDayBuild, we turn your idea into something tangible in one day for €1,150, so you can see whether further development is worth the investment. Decide to go ahead with the full build? Then we credit the full cost.
Explore OneDayBuild →Technology and integrations
This page is about recording defects. For the plastics industry as a whole, see our plastics industry software page; for production monitoring, our page on a MES system; and for scheduling based on actual cycle times, our page on an app for injection moulding scheduling. You can read about how we work at getting software built.
Why choose Appfront for your injection moulding scrap-tracking software?
Scrap that is not recorded is not reduced. We build on that: every reject with its cause, the conditions around it, and the costs in view.
Cause instead of a number
You see not only how much scrap there was, but why and at which cavity. Improvement starts with the largest cause.
Wear spotted early
A mould that gradually produces more flash shows up in the trend, before a customer complains.
Costs that count
Scrap per product in money shows clearly where an improvement will deliver the most.
Security and privacy for injection moulding scrap-tracking software
The software holds production data, process settings and customer orders: confidential knowledge of your business. Access is set by role: the operator records, the shift supervisor sees their shift, and quality and engineering handle the analysis. Records are logged with name, machine and time.
The software runs on your own server or in a European data centre, with encrypted storage and daily back-ups. The integration with machine controls is read-only.
Frequently asked questions about injection moulding scrap-tracking software
Questions injection moulders ask before getting started.
It records scrap at the machine per order, mould and cavity with a cause code, separates start-up scrap from production scrap, pulls counts and process parameters from the machine where possible, analyses scrap per machine, mould, material and shift, and calculates the costs.
Many modern injection moulding machines expose counts and process parameters through a standard integration. We'll look at which machines and controls you have in the first step. Older machines can still be included through manual logging.
No. On a terminal or tablet at the machine, the operator selects the cause and the quantity in a few taps. Machine, order and mould are already filled in.
A MES tracks the whole production process, with orders, counts and machine status. This software goes deeper into scrap and its causes. If you have a MES, scrap recording can connect to it.
Yes, provided the operator selects the cavity or the product indicates it during recording. That way, a cavity that deviates stands out from the rest.
Include the material weight, material price, machine time and your hourly rate. Regrind can be credited.
Check that first. Many MES systems record good and bad parts, and some also record a cause. That's enough if you only need totals. Custom development makes sense if you want scrap per cavity and cause shown alongside process parameters, or if your MES can't do this without expensive add-ons.
Scrap with its cause, and the costs attached?
Tell us how many machines and moulds you have, how you currently record scrap and which systems you use. We'll show you what the recording, analysis and costing would look like.