One ERP. Every Industry. Global Presence. Powered by Azaalea AI
One ERP. Every Industry. Global Presence. Powered by Azaalea AI
Plastic Manufacturing
Specialized ERP for blow molding, injection molding, and rotomolding processes. Track batches, formulations, machine efficiency, quality parameters, and full traceability from raw material to finished goods.
Scheduling, Scrap, and Speed—All on One Screen
How a multi-plant plastics manufacturer unified three processes and gained real-time control
The Challenge
A multi-plant plastics manufacturer ran blow, injection, and rotomoulding under a single brand but with disconnected tools. Resin lot traceability stopped at the silo; color masterbatch variants lived in spreadsheets; changeovers were planned on wall charts; and regrind, scrap, and mold life tracking were inconsistent. As orders surged, planners struggled to align molds, machines, crews, and materials.
Pain Points:
- Long changeovers and frequent production expedites
- Excessive work-in-progress (WIP) inventory
- Customer promises slipped when machines went down or molds missed preventive maintenance
- Finance saw margin swings but lacked visibility into cycle time, scrap reasons, or rework costs by mold and item
Implementation: 9 Weeks
With eresource ERP + Azaalea No-Code, we configured (not coded) mold/tool masters, machine calendars, preventive maintenance plans, and resin/masterbatch lot rules. Dispatch lists shifted from paper to tablets; barcode/QR scans captured issue/return, regrind usage, and rejects by reason code. Planners gained a finite schedule board with drag-and-drop; quality checks slotted at start-up and at defined part counts.
What we configured:
- Mold/tool masters with life tracking
- Preventive maintenance plans
- Barcode/QR scanning for floor control
- Quality checks at start-up & intervals
- Machine calendars and schedules
- Resin/masterbatch lot rules (FEFO)
- Drag-and-drop schedule board
- Regrind usage and scrap tracking
Post-go-live, the shop floor worked to a single source of truth: work orders carried correct cycles and cavitation; tool life and PM counters blocked risky runs; FEFO on resin lots prevented aging stock; and variance dashboards illuminated where time and material were being lost. Maintenance integrated with production—PMs auto-scheduled off the plan, not the calendar.
Results & Impact
Measurable Scrap & Rework
What was once guesswork became trackable—and improvable
Reliable Delivery Dates
Customer service gained accurate EDDs backed by real-time shop floor data
Financial Visibility
Finance tied actuals back to molds, machines, and materials in one place
Business-Driven Expansion
Adding a new product family or machine is now a business action, not a development project
Ready to Write Your Success Story?
See how eresource ERP can transform your manufacturing operations in weeks, not months
Email: sales@eresourceerp.com · Website: www.eresourceerp.com