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Image shows process data analysis in the ENGEL customer portal

Process monitoring with AI in injection moulding

Optimise processes and avoid rejects with iQ process observer

The AI-supported software solution iQ process observer continuously monitors all five phases of the injection moulding process: plasticising, injection, cooling, demoulding and production. Hundreds of process parameters are continuously recorded and analysed. 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 deployment of skilled workers
Figure displays icon for target

Thanks to data analysis with AI, process data is optimally organised and the focus is placed on current deviations. This allows experts to be employed efficiently and counteracts the shortage of skilled workers.

Avoid rejects at an early stage
Figure displays ICON for early detection of process deviations

AI-supported process monitoring detects process deviations at an early stage before rejects occur. As soon as a deviation is identified, the iQ process observer instantly provides a data-based recommended action – without the need for time-consuming and costly test series.

Single monitoring of process stability
Figure displays ICON for process stability

The iQ process observer continuously examines the process stability of your machine and enables continuous process monitoring as a basis for data-driven decisions. Data analysis with AI allows processes to be optimised in a targeted and guided manner. Process stability is increased in the long term.

Process data available anywhere, anytime
Image shows ICON for global access

The iQ process observer is available on the control unit and online. This allows you to access your process data from anywhere. With the web-based version, AI-supported data analysis can be tracked over a longer period of time.

Functions of iQ process observer

Image shows process monitoring with iQ process observer Image shows process monitoring with iQ process observer

Capture the process status at a glance

The iQ process observer makes complex production processes simple to understand by clearly visualising the current process status along the five process phases. Automatic data analysis with AI continuously evaluates hundreds of process parameters in real time and detects process deviations at an early stage. Traffic light signals show at a glance whether the process is running stably and how target value changes impact the overall process – without any prior configuration.

Image shows display of the process reference state Image shows display of the process reference state

Define reference values with a single click

With just one click, the iQ process observer sets 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 complies with the reference state and which deviations cause potential quality changes.

Image shows display of process changes and optimisation suggestions Image shows display of process changes and optimisation suggestions

Detect reasons and reach a solution

The iQ process observer supports you in root cause analysis and process optimisation. Based on intelligent algorithms, supplemented with integrated expert knowledge, process data analysis identifies deviations and reveals optimisation potential. Clear indications of anomalies, combined with possible causes and concrete solutions help identify weaknesses in the process quicker enabling a rapid, sustainable resolution.

Image shows process monitoring directly on the CC300 machine control unit

Process monitoring at the machine control

iQ process observer available directly on the machine

All functions of the iQ process observer are also available directly on the machine control unit (from CC300 onwards). Thanks to minimal configuration needed, the solution can be activated quickly and enables instant, transparent monitoring of the injection moulding processes in your production.

Image shows Head of Product Management Digital Solutions at ENGEL Austria
Would you like to benefit from AI-supported process monitoring in your organisation?

Our experts will be happy to advise you!

Request a solution now

How AI supports process monitoring in injection moulding

AI simplifies process monitoring, continuously learns and reduces manual quality checks. This leads to stable, transparent processes and efficient labour use.

Automatic process window

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

Pattern & anomaly detection

By continuous data analysis with AI, the system detects deviations and trends at an early stage – before they affect component quality or generate rejects. The system learns from new process data and permanently adapts its evaluations.

Intelligent recommendations for action

Complex process data is automatically evaluated using AI and translated into clear, understandable recommendations for action. These can be applied directly in everyday production.

What Our Customers Say About iQ process observer

Image shows Technical Director at Kunststofftechnik Borgmann GmbH

The time needed to analyse process errors and quality checks has been reduced by 30 minutes per day and 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 control a stable process and the required quality. It is currently running perfectly.

Dariusz Barton, Managing Director at SolidPlast
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Picture shows process technicians at Schöfer

I no longer have to rely solely on my gut feeling as to which process parameters need to be changed so that no rejects are produced. This saves me time when troubleshooting. Depending on the cycle time, this saves me up to 30 minutes, which I can use for other tasks.

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

    Thanks to the iQ process observer, Borgmann has reduced the internal effort required to analyse process errors and quality checks by 30 minutes per day and machine.

  • Support in process optimisation in the event of a shortage of skilled workers

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

  • User report from BIC Violex, Greece

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

  • User report from Schöfer, Austria

    30 minutes faster in finding solutions

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ENGEL Team

Sales

Write to us

The ENGEL team will be happy to assist you with comprehensive know-how on the subject of injection moulding.
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