Plastic moulding companies across India and global markets increasingly face pressure to deliver high-precision products at competitive rates. The challenge intensifies when dealing with industries like automotive, FMCG, electronics and medical manufacturing, where even minor defects or dimension variations can trigger costly rejections.
Despite advanced machines and skilled teams, many moulding units still maintain production logs manually, lack real-time data and rely on post-production inspection rather than preventive quality measures. These factors collectively increase rejection rates, slow down production cycles, and reduce profitability.
Odoo’s Quality Control and Manufacturing Execution System (MES) modules bring a structured, automated framework that helps plastic moulding units predict, prevent and eliminate defects instead of reacting to them. Techmatic Systems specializes in implementing Odoo for moulding industries, enabling companies to build manufacturing workflows that drastically reduce rejection percentages.
Understanding Rejection Problems in Plastic Moulding
The plastic moulding process whether it’s injection moulding, blow moulding or compression moulding—requires consistent machine settings, controlled temperatures, accurate cycle times and precise handling. Any deviation can lead to batch rejections or rework, drastically affecting throughput.
Common rejection causes include:
- Inconsistent curing or heating
- Incorrect cycle timing
- Over-packing or under-packing
- Imbalanced pressure or material flow
- Tooling wear and tear
- Poor quality raw materials
- Lack of real-time machine data
- Missing preventive maintenance schedules
These issues often go undetected until inspection, resulting in high rejection percentages, wasted manpower and increased cost per unit.
Odoo solves these problems by transforming the moulding floor into a data-driven, automated and quality-focused environment.
How Odoo Reduces Rejection Rates in Plastic Moulding
Odoo combines MES, Quality, Maintenance and Inventory modules to create a complete production ecosystem. This ensures defects are caught at the source, not at the end of the line.
Here’s how Odoo drives rejection reduction:
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Real-Time MES Monitoring on the Shop Floor
Odoo’s MES module connects operators, machines and supervisors in real time. It displays live work orders, machine cycle status, scrap generation and performance metrics.
Benefits:
- Detect issues instantly
- Reduce downtime and deviations
- Maintain consistent production cycles
- Monitor operator performance
- Track shift-wise variations
This continuous visibility helps operators correct problems before defective parts accumulate.
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Quality Checks at Critical Control Points
Instead of performing quality checks only after production, Odoo inserts QC checkpoints throughout the cycle.
Quality parameters tracked:
- Dimensions
- Wall thickness
- Visual defects
- Temperature & pressure logs
- Gate marks
- Warping, short shots, burn marks
- Color variance
If a parameter fails, Odoo automatically:
- Blocks the batch
- Initiates a corrective action
- Alerts supervisors
This prevents large-scale rejections and saves material cost.
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Digital Work Instructions & Standardized SOPs
Odoo stores all:
- Machine settings
- Tooling setups
- Material specifications
- Process guidelines
Operators receive clear digital instructions for each product setup, reducing variation caused by human error.
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Machine and Tool Maintenance Scheduling
Machine wear is a hidden cause of defects.
Odoo Maintenance automates:
- Preventive maintenance
- Tool calibration schedules
- Die cleaning and inspection
- Lubrication checks
- Part replacement alerts
This ensures machines consistently produce accurate parts and reduces defects caused by mechanical deterioration.
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Traceability from Raw Material to Finished Component
Odoo tracks every batch of raw material, color additives and semi-finished goods through:
- Lot traceability
- Barcode/QR scanning
- Batch-based production routing
If defects arise, root causes can be traced instantly.
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Scrap Analysis and Real-Time Reporting
Odoo gives detailed insights into:
- Scrap reasons
- Scrap volumes
- Machine-level defects
- Operator-wise rejection
- Material wastage patterns
With accurate scrap analytics, companies can take immediate corrective actions.
Case Study 1 — Injection Moulding Unit, Gujarat
A Gujarat-based plastic moulding company supplying automotive components struggled with a high 12–15% rejection rate due to inconsistent temperatures, manual log tracking and delayed QC reporting.
Techmatic Systems’ Odoo Implementation Included:
- MES dashboards for real-time machine cycle visibility
- QC checkpoints for critical moulding stages
- Tool maintenance scheduling
- Digital work instructions for operators
- Automated scrap analysis reporting
Results Achieved:
- Rejection rate reduced from 15% to 6%
- Real-time machine insights prevented 30+ breakdowns
- QC reporting accuracy improved dramatically
- Better operator performance consistency
Real-Time Case Study 2 — FMCG Packaging Moulder, Tamil Nadu
A mid-sized moulding unit producing plastic bottles for FMCG brands faced recurring defects such as short shots, flashings and shape deformation.
Problems Identified:
- No MES system
- Inconsistent operator inputs
- Improper material mixing ratios
- Delay in detecting dimensional defects
Odoo Solution Implemented by Techmatic Systems:
- Automated dimensional QC using digital forms
- Raw material and masterbatch traceability
- MES-driven real-time alerts for deviations
- Maintenance reminders for moulds and dies
Impact:
- Rejections reduced by 40% within four months
- Cycle time consistency improved
- Raw material wastage dropped significantly
- Better customer acceptance for bulk orders
Techmatic Systems’ Implementation Approach
Our approach ensures that moulding units adopt Odoo seamlessly and gain measurable results.
Our 6-step deployment framework:
- Process Study – Understanding moulding cycles, QC points, machine behavior and tooling.
- Module Setup – Configuring MES, QC, Maintenance, Inventory and MRP modules.
- Production Workflow Design – Creating product-specific routing and QC checkpoints.
- Machine & Tool Integration – Setting up cycle logs, calibration schedules and performance tracking.
- Operator Training – Ensuring teams know how to execute work orders via Odoo terminals.
- Go-Live Optimization – Refining dashboards, scrap analytics and automated triggers.
Defects in plastic moulding not only inflate costs but also damage brand credibility. With Odoo’s integrated Quality and MES automation, moulding units can detect issues early, maintain consistent output and drastically reduce rejection rates. Techmatic Systems brings proven expertise to ensure your moulding shop operates with precision, transparency and maximum productivity.
