The plant dashboard for plastics and rubber
Continuous injection, extrusion and blow moulding.
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- 8 standard bays loaded
- 6 lockout energy sources
- 5 reference standards
How the work is done in plastics
A closed machine with a lot of energy inside: the mould closes with tonnes of force, the screw burns and molten material does not wait. The delicate work is in the mould change and the purge.
The jobs that set the pace
- Mould change and set-up
- Purge and material change
- Maintenance of mould temperature controllers and chillers
- Mill cleaning
- Robot and peripheral set-up
The bays it comes with as standard
- Injection moulding bay
- Extrusion
- Blow moulding
- Blends and masterbatch
- Mills and in-house recycling
- Pellet store
- Mould shop
- Dispatch
Lockout/tagout, with isolation point and verification
The dashboard does not ask “what energies does your equipment have?”: in the plastics profile they are already there, each one with where it is isolated and how you check that it is isolated. It is what an inspection asks to see in writing.
| Energy | Isolation point | Verification |
|---|---|---|
| Electrical | Machine panel isolator | Verification of the absence of voltage and discharge of the drive |
| Thermal | Isolation of the screw and barrel heaters | Contact pyrometer below 60 °C |
| Hydraulics | Valve of the injection moulding machine power pack | Accumulator discharge and mechanical chocking of the platen |
| Pneumatic | FRL unit with lockout | Circuit bled, gauge at 0 bar |
| Stored mechanical energy | Chocking of the moving platen and the mould | Visual check of the chock before entering between platens |
| Cooling water | Mould temperature control valves | Bleed and check pressure at 0 |
The high-risk procedures, written down
Five procedures specific to plastics, written in the vocabulary of the sector and available inside the dashboard so you can adapt them to your plant.
Entry between platens
Electrical and hydraulic lockout, accumulator discharge and mechanical chocking: the guard is not enough when energy is stored.
Injection moulding machine purge
Molten material under pressure: face shield, thermal PPE and never purge towards a person.
Mould change with the overhead crane
Clamps checked, mould balanced and hands out of the closing plane.
Work on the mills
The rotor keeps cutting as it coasts: lock out, wait for a verified complete standstill and lock the cover.
Work with milling dust
Cleaning without compressed air and with extraction: a cloud of fine dust is an explosive atmosphere.
Equipment and reference regulations
Equipment typical of this profile
- Injection moulding machine
- Extruder
- Blow moulding machine
- Crushing mill
- Mould temperature controller
- Water chiller
- Screw compressor
- Overhead crane in the mould shop
- Cartesian robot
Regulations that frame the work
- RD 1215/1997 · work equipment
- UNE-EN ISO 12100 · safety of machinery
- RD 681/2003 · ATEX (milling dust)
- RD 374/2001 · chemical agents
- RD 842/2002 · electrotechnical regulation
Current references the dashboard uses to organise the documentation. IndustriaKit is a documentation tool: it does not replace the risk assessment or legal advice.
- Mould maintenance plan
- ATEX assessment of the mill area
- Safety data sheets for additives and masterbatch
What the dashboard does with all this
Contractors and coordination of activities
Contractors working on site join free, upload their documentation and the traffic light decides who can work. RD 171/2004 coordination with minutes and signature.
Permits with QR codes
Work permit with a printable notice: in the field it is scanned and signed from a phone. LOTO warning when the job calls for it.
Maintenance and OEE
Queue prioritised by criticality, statutory maintenance schedules with their date, counters based on real usage and an OEE panel per line with a Pareto of stoppages.
Personnel and training
Fitness for work, training and health surveillance by job role, with the medical data kept outside the dashboard by design.
Open it with the plastics profile and compare it with your folder
The demo opens with no card and no sales call. You choose this same sector and walk into a plant that looks like yours, with sample data you can play with without breaking anything.
The other industries in the dashboard
Each profile brings its own vocabulary, its own areas, its own energies and its own procedures. There are sixteen.