🏭 Industry · Plastics & Injection Moulding
Your average looks fine. Which machine is hiding behind it?
What each machine is really rejecting. How many hours were lost waiting for moulds. How fast you can trace a batch back to its resin lot.
One moulder found a single machine rejecting at 9.2% while the others sat under 2.5%. The monthly average had hidden it for a year.
Plastics manufacturers, mould-wise rejection tracking live
As featured in PrintWeek India, April 2026 ↗
Three moulders. Each one had an average that was hiding an outlier.
01 Rejection, machine by machine
Every moulder knows his overall rejection percentage. Almost none know it per machine, per mould, per shift.
So a mould that has drifted out of tolerance keeps running, and the rejection is absorbed into a monthly average that looks acceptable.
Rejection by machine, one month
M11.8%
M22.3%
M39.2%
M41.9%
Shots in and good parts out are recorded per machine, per shift. The average stopped hiding the outlier.
9.2% → 2.6%after the mould was corrected
Find out howBring last month. Fifteen minutes.
02 The mould that was not ready
A job is planned. The mould is in the tool room, or on another machine, or waiting for a repair nobody logged.
The machine sits idle while somebody goes to find out. Mould availability was never part of the plan, it was assumed.
Machine idle time, one month, why
Waiting for mould38 hrs
Waiting for material17 hrs
Changeover20 hrs
Breakdown9 hrs
Mould status became a field on the job. A job cannot be scheduled onto a machine whose mould is not confirmed free and fit.
38 hrs → 11 hrsidle waiting for moulds
Show me howFifteen minutes. We add the mould check.
03 Material, batch and the complaint
A customer reports a batch failing. You need to know which resin lot went into it, which machine ran it, and what else used the same lot.
That answer exists across a store register, a production sheet and somebody's memory. Assembling it takes a day.
Time to answer one batch complaint
From paper records7 hrs
From spreadsheets2.8 hrs
Tracked at each shot5 min
Resin lot, machine and shift attach to the batch as it is produced, so the trace is a filter rather than an investigation.
A day → minutesto answer any complaint
Show me howFifteen minutes. We trace one live.
An average is a comfortable number. It is also where problems go to hide.
Your Production Flow
Every shot. Every rejection. Every mould tracked.
This is how a print job moves through your business. Clicarity gives you live visibility at every phase, and flags delays before they become client calls.
01
Order & Planning
4 stages
Order Received
Customer order confirmed, part number, material, quantity, colour, and deadline.
✓ Clicarity: Job ID created, mould assigned, material planned
Material Planning
Raw material grade, colour master batch, and additives specified per job.
⚠ ⚠ Common delay: wrong grade or colour, discovered only when first shots produced
Mould Setup & Allocation
Mould pulled from store, fitted on machine, and trial shots taken.
⚠ ⚠ Common delay: mould condition poor, maintenance required before production starts
Material Procurement
Granules, master batch, and additives procured or pulled from inventory.
✓ Clicarity: Material lot number recorded, traceability from granule to part
02
Pre-Production
3 stages
Material Drying
Hygroscopic materials dried in hopper dryer to required moisture content.
⚠ ⚠ Common delay: inadequate drying, splay defects in first production run
Machine Setup & Trial
Temperature, pressure, speed, and cooling parameters set and trialled.
✓ Clicarity: Setup parameters logged, reproducible for next run
First Article Inspection
First production parts inspected for dimensions, appearance, and function.
⚠ ⚠ Common delay: first article fails, parameter adjustment adds hours before production
03
Moulding Production
4 stages
Injection Moulding
Parts produced on injection moulding machine, shot by shot, cycle by cycle.
✓ Clicarity: Shot count, good parts, and rejections logged per shift per mould
In-Process Inspection
Sample parts pulled at regular intervals for dimensional and visual check.
✓ Clicarity: Rejection rate tracked live, spike alerts before full run is affected
Runner / Sprue Segregation
Runners and sprues segregated for regrind, regrind percentage tracked.
✓ Clicarity: Regrind quantity logged, excessive regrind flagged automatically
Packing & Counting
Good parts counted, packed in boxes, and labelled per customer requirement.
✓ Clicarity: Running count vs order quantity tracked, shortfall visible live
04
Secondary Operations
4 stages
Trimming / Degating
Gates, flash, and excess material trimmed from moulded parts.
⚠ ⚠ Common delay: excessive flash, mould maintenance required, delays assembly
Assembly
Moulded components assembled with other parts, inserts, screws, sub-assemblies.
⚠ ⚠ Common delay: one moulded component rejected, entire assembly batch held
Printing / Pad Printing
Text, logos, or markings pad printed on finished parts.
Ultrasonic Welding
Plastic parts welded using ultrasonic welding machine.
✓ Clicarity: Weld quality check logged per batch, failure rate tracked over time
05
Quality & Dispatch
3 stages
Final QC
Finished parts inspected for dimensions, appearance, function, and assembly fit.
✓ Clicarity: Final rejection rate by part number tracked across batches
Packing & Labelling
Parts packed in customer-specified packaging with part number and quantity labels.
✓ Clicarity: Packed quantity vs order confirmed before dispatch
Dispatch
Parts dispatched with delivery challan and inspection certificate.
✓ Clicarity: Full batch history, from material lot to dispatch, preserved
Real Printing Business. Real Results.
""Our rejection rate looked fine on the weekly report, 4.2% overall. But when we tracked it by mould, one mould was running at 18% rejection and dragging the average down. We would never have found it without stage-wise tracking.""
What improves in plastics businesses using Clicarity
↓ 65%
Rejection rate on flagged moulds
↑ 28%
Machine utilisation improvement
↓ 50%
Assembly stage idle time
5 days
To go live, full setup included
Questions from plastics businesses
How does Clicarity work for a printing business specifically?
Clicarity is configured around your specific print workflow, pre-press, printing, finishing, dispatch, in your terminology. Every job gets a unique ID and moves through your defined stages. You see live status, timestamps, and alerts when a job sits too long at every stage. The Clicarity team builds everything for you. You go live in 5 days.
Does it work for both offset and digital printing?
Yes. Clicarity works for any print process, offset, digital, wide format, screen printing, or a combination. The stages are configured around your actual workflow. If offset jobs go through plate making and digital jobs skip that stage, both can be tracked correctly under the same system.
Can it track material wastage at each stage?
Yes, with the Multi Licence. At every stage, your team logs quantity in and quantity out. Clicarity calculates the loss automatically. You see wastage by stage, by job, live, not at month-end when nothing can be done about it.
Will my press operators actually use it?
Yes. The update screen has two fields. Job ID and status. Under a minute. No training needed. GP Offset's entire team was using it from day one, including floor workers who had never used a software system before.
See every mould. Every rejection. While you can still act.
Book a free demo. We'll map your moulding workflow live on the call.
No commitment
Live in 5 days
Annual licence
Full setup included