Correct mold matching,
zero defect production.
In the project implemented at Maxion Inci Steel's wheel factory in Manisa, production molds were tracked with an RFID-based system. The project aimed to ensure correct matching of molds based on recipes and prevent the use of incorrect molds.
Mold control and process security in wheel production
In the project implemented at Maxion Inci Steel's wheel factory in Manisa, production molds were tracked with an RFID-based system. The project aimed to ensure correct matching of molds based on recipes and prevent the use of incorrect molds.
Ensuring mold accuracy in production is of critical importance for product quality and line efficiency.
Incorrect mold usage and quality risks
In wheel production, it had to be guaranteed that the mold suitable for each recipe was used. Manual mold selection brought the risk of incorrect mold usage and related quality/scrap issues. In addition, the inability to reliably monitor the useful life of molds made maintenance and planning difficult.
- 01Mold Matching ErrorsThe risk of starting production with the wrong mold due to manual controls, leading to scrap.
- 02Mold Life Tracking DifficultyInability to automatically track mold stroke cycles and maintenance schedules.
PLC integrated operation permit with RFID reading
In the project using RFID equipment, integration with the existing PLC was provided to match molds on a recipe basis, preventing the use of incorrect molds. During recipe changes, mold IDs are read via RFID to verify matching; when matched, the machine is granted permission to operate. Mold lifetimes are also tracked through the RFID-based system.
Recipe Input
The wheel production recipe is selected from the PLC system by the operator.
RFID Mold Reading
The RFID tag on the mold is scanned by the RFID reader on the wheel machine.
Logical Verification
The PLC system compares the read mold ID with the recipe requirements.
Operation Permit
When the match is correct, the machine is permitted to run and production starts.
Industrial RFID and PLC infrastructure
Boron-Oil Resistant RFID Tags
RFID tags with high durability against boron oil and chemicals in harsh production environments.
RFID Devices and Readers
RFID hardware reading mold IDs precisely and transmitting them to the PLC.
Existing PLC Integration
PLC system logically comparing mold data with recipes and unlocking the machine.
Mold Life Tracking Module
Software layer tracking lifetime and planning maintenance according to mold cycle counts.
Field PLC and Logical Lock Integration
The system runs integrated with the customer's existing PLC infrastructure. After the mold ID is scanned and verified via RFID, the PLC logical lock is opened, allowing the machine to run.
Error-free production and data-driven maintenance
Zero Wrong Molds
Incorrect mold usage is completely prevented thanks to automatic RFID matching and PLC locking.
Quality and Scrap Savings
Production scrap and quality deviations resulting from incorrect mold installations are eliminated.
Predictive Maintenance
Mold maintenance planning has become data-driven by tracking mold lifetimes and stroke counts.
Meet Our End-to-End Traceability Solution
OnSuite Trace allows you to manage all your production processes from a single platform. We provide end-to-end digital traceability for your business with the motto "Continuous Control, Zero Defects".
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