Visibility & Production Control


Evco Plastics, headquarted in DeForest, Wisconsin, is a global high precision molder with over 129 machines, over 1,000 employees; capable of ISO 8 clean room certification, robotics driven automation, and assembly.

Executive Summary

Dale Evans, the president of EVCO Plastics, a custom plastic molding manufacturer, wanted to track and monitor the molding status of each of his 129 presses in eight facilities.



The Challenge

Companies often have a reactive approach regarding production control—they wait until a part fails QA inspection to find a faulty process or depend on opinions of what went wrong. EVCO Plastics wanted to take a more proactive approach by implementing accurate, real-time data collection on their 129 presses operating in eight plants in the United States and Mexico.


Molding Machines

Years of PlantStar Use


SYSCON-PlantStar implemented , their top-tier production monitoring system, in eight EVCO Plastics facilities. A Data Collection Module (DCM) at each injection molding press gathers OEE-related data and sends the information to a shared PC-based server. Each press is represented on screen with a status bar, colored to indicate the machine’s status. If the molding process falls out of tolerance, the status bar changes and an audio page is announced in the plant. The machine status bars are also displayed throughout the plant on video monitors. In addition, the system recognizes out-of-tolerance cycles, job status and many other variables and displays the information in easy-to-read screenshots.

Panorama’s job scheduler function enables managers to schedule jobs for every press. Operators can schedule by part date, drag and drop orders from machine to machine, and schedule downtime. Managers can see bottlenecks and potential scheduling problems before they occur. Supervisors use the system to do SPC analysis, job costing and forecasting. Panorama’s open architecture allows EVCO Plastics to share plant floor data with its MRP system.

Initially, machine operators were hesitant to adopt the audio and monitoring systems. Now they see the system as a tool to proactively manage any problems, and they better understand how to optimize their jobs and raise productivity.




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