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Picture shows process data analysis in the ENGEL customer portal

Process monitoring with AI in injection molding

Optimize processes and reduce rejects with iQ process observer

The AI-supported software solution iQ process observer continuously monitors all five phases of the injection molding process: plasticizing, injection, cooling, demolding, and production. Hundreds of process parameters are captured and analyzed in real time. The results of the AI data analysis are clearly displayed on the machine control system and in the e-connect customer portal.

Your advantages of AI-supported process monitoring

Targeted use of skilled workers
Figure displays Icon for target representing AI-supported process optimization in injection molding

Data analysis with AI prepares process data clearly and highlights current deviations. This enables experts to focus on the issues that matter most, improving efficiency and helping manufacturers address the ongoing shortage of skilled workers.

Avoid rejects at an early stage
Figure displays Icon representing early detection of process deviations in injection molding

AI-supported process monitoring detects deviations early, before rejects occur. As soon as a deviation is identified, iQ process observer provides an immediate, data-based recommendation for action, without the need for time-consuming and costly trial runs.

Continuous process monitoring for stable production
Figure displays Icon representing process stability monitoring in injection molding

iQ process observer enables continuous process monitoring by visualizing the stability of your injection molding process. Integrated process data analysis supported by AI data analysis identifies deviations and provides a reliable basis for data-driven decisions and targeted process optimization.

Process data available anywhere, anytime
Figure displays Icon for global access to process monitoring and process data

iQ process observer is available on the control unit and via the web. This allows you to access your process data from anywhere. The web-based version, enables long-term AI-supported data analysis and provides deeper insight into process performance over time.

Functions of iQ process observer

Figure shows process monitoring with iQ process observer in injection molding Figure shows process monitoring with iQ process observer in injection molding

See the process status at a glance

iQ process observer makes complex production processes easy to understand at a glance by clearly visualizing the current process status across all five phases of the injection molding process. Automatic data analysis with AI continuously evaluates hundreds of process parameters in real time and detects process deviations at an early stage. Traffic light indicators show immediately whether the process is running stably and how changes to target values affect the overall process, without any prior configuration.

Figure displays the process reference state in iQ process observer Figure displays the process reference state in iQ process observer

Define reference values with a single click

With just one click, the iQ process observer defines reference values for hundreds of process parameters and, if desired, creates a complete snapshot of the optimal process. Process monitoring then clearly shows whether the current process matches the reference state and identifies which deviations may lead to potential quality changes.

Figure displays process changes and optimization suggestions in iQ process observer Figure displays process changes and optimization suggestions in iQ process observer

Detect reasons and arrive at a solution

iQ process observer supports root cause analysis and targeted process optimization. Based on intelligent algorithms and integrated expert knowledge, process data analysis identifies deviations and reveals optimization potential. Clear indications of anomalies, combined with possible causes and recommended actions, help users identify process weaknesses faster and resolve them efficiently and sustainably.

Image shows process monitoring on the CC300 machine control syston the CC300 machine control system

Process monitoring at the control unit

iQ process observer available directly on the machine

All functions of iQ process observer are also available directly on the machine control system (from CC300 onward). With minimal configuration effort, the solution can be activated quickly and enables immediate, transparent monitoring of the injection molding processes in your production.

Figure shows Head of Product Management Digital Solutions at ENGEL Austria
Would you like to also use AI-supported process monitoring in your company?

Our experts will be happy to advise you.

Request a solution now

How AI supports process monitoring in injection molding

AI simplifies process monitoring, continuously learns from production data, and reduces the need for manual quality checks. The result is more stable, transparent processes and more efficient use of skilled labor.

Automatic process window

The AI independently identifies stable process ranges and defines appropriate tolerance limits. This enables reliable process monitoring without manual readjustment.

Pattern & anomaly detection

Through continuous AI data analysis, the system detects deviations and trends at an early stage before they affect component quality or lead to rejects. The system continuously learns from new process data and adapts its evaluations over time.

Intelligent recommendations for action

AI automatically evaluates complex process data and translates it into clear, easy-to-understand recommendations for action. These insights can be applied directly in everyday production.

What Our Customers Say About iQ process observer

Image shows Technical Director at Kunststofftechnik Borgmann GmbH

The internal effort required for process error analysis and quality inspections has been reduced by 30 minutes per day and per machine.

Stefan Borgmann, Technical Director at Kunststofftechnik Borgmann GmbH
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Picture shows managing director at SolidPlast

I can say that the iQ process observer is exactly the right tool for us to ensure a stable process and maintain the required quality. Right now, everything is running perfectly.

Dariusz Barton, Managing Director at SolidPlast
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Picture shows Process Technician at Schöfer

I no longer have to rely solely on my intuition to determine which process parameters need to be adjusted to avoid producing rejects. This saves me time when troubleshooting. Depending on the cycle time, this could free up to 30 minutes for me to use for other tasks.

Niclas Lugmayr, Process Technician at Schöfer
  • How the iQ process observer saves 30 minutes per machine every day

    At Borgmann, the internal effort for analyzing process errors and quality inspections has decreased by 30 minutes per machine daily, thanks to the iQ process observer.

  • Support in process optimization in response to skilled labor shortages

    Thanks to comprehensive data analysis by iQ process observer, even less experienced machine operators benefit from automated recommendations for process optimization.

  • Customer review from BIC Violex, Greece

    BIC was able to increase the already high OEE by 3% and reduce the reject rate by more than 40%. Learn how products from the ENGEL inject 4.0 portfolio contributed to this success.

  • User report from Schöfer, Austria

    30 minutes faster in finding solutions

What else you might be interested in

Additional digital solutions for your production

Image shows customer portal

Customer Portal

e-connect

Your online portal for an overview of your machines - at any time. Easily keep an eye on current service cases, monitored components or upcoming appointments.

Learn more
Picture shows monitoring of production in the e-connect portal

Production monitoring

shopfloor monitoring

  • Analyze production data retrospectively

  • Identify optimization potential at the push of a button

  • Independent of the manufacturer

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Control processes digitally

authentig

The machine data acquisition software provides information about productivity, on-time delivery and production quality.

Learn more
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Digital solutions

  • Optimization of injection molding processes along the product life cycle

  • Networking across the system

  • Utilize the full potential of your production

Learn more
Picture shows digital solutions for injection molding ENGEL

Production

With intuitive software solutions, you have your production in view, exploit all potentials and support your employees.

Learn more

Markus Lettau

Sales

+1 (717) 767 2016

Write us

The ENGEL team is happy to support you with extensive knowledge in the field of injection molding.
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