Plastics, rubber & packaging

Smart manufacturing for plastics, rubber & packaging.

Extrusion, moulding, dipping and converting lines change products often, and every change burns material and line time. DMIS finds the cheapest production sequence, links settings to off-spec output and puts a ringgit value on every loss.

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The challenge

Where plastics, rubber and packaging plants lose margin.

Colour and grade changes

Purging and start-up after each change waste material and hours of line time, set by habit rather than data.

Off-spec output

Thickness, weight, colour or strength problems show up after the product is made.

Process drift

Temperatures, speeds and pressures drift between shifts and operators, and so does quality.

Unplanned downtime

Breakdowns and short stops on moulds, dies and lines keep OEE low and nobody knows which cost most.

How DMIS helps

Smart manufacturing, configured for plastics, rubber and packaging.

DMIS is a smart manufacturing platform, not a fixed product. It starts from the records you already keep, with no new sensors, and is configured to your products, machines and KPIs.

AI production sequencing

DMIS builds a changeover matrix from your own records and recommends the weekly sequence with the least waste.

Setting recommendations

Models link process settings to quality results and suggest changes that lower off-spec risk for the next run.

Process simulation

Test a setting change on a physics-informed simulator before trying it on the line.

Loss analytics

See purge, scrap and downtime losses by line, product and shift, costed in RM.

What you measure

The KPIs that matter in plastics, rubber and packaging.

Every KPI is calculated from your own data, by line, shift and product, and every loss is costed in ringgit so you know what to fix first.

Changeover and purge time and waste
Scrap and off-spec rate by product
OEE by line, machine and mould
Process settings against quality results
Energy and material per good unit
Lot traceability to resin or compound

Example

What this looks like on the floor

An extrusion line runs ten products a week in a fixed order. DMIS calculates the purge waste of every possible change from past records and recommends a new sequence. The plant cuts changeover waste without new equipment, and the saving is tracked every week.

An illustrative example. Results in your plant are measured during the pilot.

Integrity

Consistent quality your customers can check.

Packaging and component makers often supply food, medical or automotive customers with strict requirements, and rubber products face their own export standards. DMIS keeps the validated records and lot genealogy that support those audits.

Lot genealogy from raw material to finished roll, part or carton
Process settings recorded with every batch
Quality results and deviations linked to each lot
Fast answers for customer complaints

FAQ

Questions from plastics, rubber and packaging manufacturers.

Can DMIS really reduce changeover waste?

Yes. Changeover waste depends heavily on sequence. DMIS learns the cost of each change from your records and recommends the cheapest order. Our pilot target is a 10% cut in changeover waste within three months.

Does it work for rubber products, such as gloves?

Yes. KPIs, process steps and quality checks are configured to your process, whether that is extrusion, moulding, dipping or converting.

What data do we need?

Production records with product, time, settings and quality results are enough to start. These usually already exist in logbooks or spreadsheets.

Is there a simulator?

Yes. DMIS includes a physics-informed simulator, validated on several factory profiles, so recommendations can be tested before they reach the line.

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