Challenge

Some of the manufacturer's injection molding machines were not natively capable of exporting digital production data. Key performance metrics such as cycle time, injection pressure, or mold cooling durations were only visible through on-machine displays. This lack of digital access made it difficult to monitor production trends, track KPIs, or apply even basic analytics.

Solution

Simularge deployed a hybrid solution combining ConnPack (Simularge's PLC connectivity module) and VisPack (Simularge's image processing module) to capture inaccessible data.

For machines without open PLC interfaces, image processing techniques were used to extract data directly from HMI screens.

The captured visual data was converted into structured, time-stamped digital values.

These values were integrated into ConnPack allowing operators and supervisors to view them in real-time dashboards.

Data logs were also stored for historical analysis and reporting.

This approach allowed the manufacturer to bypass machine-level restrictions without modifying hardware or firmware.

Impact

• Digital access unlocked from machines previously considered “data blind”

• Non-invasive solution, no need for deep PLC integrations or machine changes

• Enhanced traceability of key production parameters

• Laid the groundwork for future process optimization and predictive analytics

The Manufacturer now has visibility into previously hidden process variables, giving their engineering and quality teams better tools for decision-making and efficiency gains.