OneSuite

INDUSTRIES · PROCESSED INDUSTRY & MANUFACTURING

Know what every part costs — shift by shift.

In a moulding shop the margin is decided in grams and seconds. OneSuite reads shot weight, cycle time, rejects and regrind from the job card, machine and QC report, turns them into a cost per part, and puts quotes, first-offs and dispatches before the person who signs.

AI POWERED PLASTICS PLANT STACK

See it for my plant

Free for the first year.

The stages a job moves through

Each stage has a gate. OneSuite checks it, and says what is missing, before anyone asks.

  1. Enquiry and costing

    Moves on when: Drawing and annual volume in; weight, cavities, cycle time and material costed.

  2. Order

    Moves on when: PO or schedule accepted at the quoted price, on dates the plan can meet.

  3. Job card

    Moves on when: Machine, mould, grade, masterbatch and regrind ratio — no start without all five.

  4. Material issue

    Moves on when: Resin and masterbatch issued by lot to the standard; anything above needs a reason.

  5. First-off approval

    Moves on when: First parts checked against the drawing and signed by QC before bulk runs.

  6. Production

    Moves on when: Shots, cycle, downtime and rejects by shift — from the machine where a counter is fitted.

  7. Inspection and dispatch

    Moves on when: Pre-dispatch inspection passed, packed to standard, invoiced with an e-way bill where required.

  8. Collected

    Moves on when: Paid against the invoice; ageing chased by customer and due date.

Every machine’s state and cycle against standard — a slow cycle seen during the shift, not in the month-end cost. Illustrative figures, drawn to show the working; not a customer’s records.

The papers that move with it

Attached to their record — so the missing one shows, and whoever owes it is the one chased.

  • Customer drawing and PO / schedule

    Revision-controlled — the job card points at the drawing being paid for.

    Stage: 02Order

  • Costing sheet

    Weight, runner, cavities, cycle, material, machine-hour rate — behind every quote.

    Stage: 01Enquiry and costing

  • Bill of materials

    Resin grade, masterbatch percentage, inserts and packing per part.

    Stage: 03Job card

  • Job card

    Machine, mould, lot, shift, shots, rejects, output — every number starts here.

    Stage: 03Job card

  • Material issue slip and supplier CoA

    Which resin lot went into which job, with the supplier’s certificate of analysis.

    Stage: 04Material issue

  • Mould history card

    Shots to date, maintenance, damage and repairs — the mould’s service record.

    Stage: 06Production

  • First-off and in-process inspection reports

    Dimensions, weight and appearance at start-up and through the run.

    Stage: 05First-off approval

  • Pre-dispatch inspection report

    Sent with the lot, generated from checks already recorded.

    Stage: 07Inspection and dispatch

  • Job-work challans, GST invoice, e-way bill and EPR records

    Moulds or material out under challan, goods invoiced, your plastics EPR kept current.

    Stage: 07Inspection and dispatch

The arithmetic, worked

From records already in the system — with illustrative figures, so you can check them by hand.

Shot weight and output

One 8-hour shift, 4-cavity lid mould. Output is set by cycle time and the minutes not running.

Part weight × cavities: 12 g × 4
48 g
Runner
4 g
Shot weight
52 g
Cycle time 24 s
150 shots an hour
Run time: 480 min less 48 min changeover and waiting
432 min
Shots in the shift
1,080
Parts moulded (1,080 × 4)
4,320
Rejected — short shots and flash
120
Good parts
4,200

Material yield and regrind

What is not a good part is runner or reject — most goes back in, up to the customer’s ratio.

Material consumed: 1,080 shots × 52 g
56.16 kg
In good parts: 4,200 × 12 g
50.40 kg
Material yield
89.7%
Runners: 1,080 × 4 g
4.32 kg
Rejects: 120 × 12 g
1.44 kg
Available as regrind
5.76 kg

Cost per part

Material net of regrind, plus machine hours, over the parts that passed.

Material: 56.16 kg × ₹120
₹6,739.20
Less regrind recovered: 5.76 kg × ₹60
−₹345.60
Machine: 8 h × ₹650 (power, operator, overheads)
₹5,200.00
Cost of the shift
₹11,593.60
Cost per good part (÷ 4,200)
₹2.76
Quoted price
₹3.10
Contribution per part
₹0.34 (11.0%)

OEE for the shift

Availability × performance × quality — a slow cycle shows as clearly as a stoppage.

Availability: 432 ÷ 480 min
90.0%
Performance: 22 s standard ÷ 24 s actual
91.7%
Quality: 4,200 ÷ 4,320 parts
97.2%
OEE
80.2%
Cost per part from what the shift actually used, not the estimate — and the quotation built on it held for the owner. Illustrative figures, drawn to show the working; not a customer’s records.

Where it stops and asks

OneSuite prepares each in full, then waits. Nothing is sent, paid or changed until the person named has seen the evidence and said yes.

BEFORE

Sending a quotation

WHO SAYS YES

The owner

WHAT THEY ARE SHOWN

The costing, the last run’s actual cost per part, and the contribution at the price.

BEFORE

Starting bulk production on a mould

WHO SAYS YES

QC

WHAT THEY ARE SHOWN

The first-off report against the drawing’s dimensions and part weight.

BEFORE

Issuing material above the job card’s standard

WHO SAYS YES

The production manager

WHAT THEY ARE SHOWN

The standard, the extra asked for, and the rejections that caused it.

BEFORE

Raising the regrind ratio

WHO SAYS YES

The QC head

WHAT THEY ARE SHOWN

The customer’s specification and the part’s recent test results.

BEFORE

Dispatching a lot with a deviation

WHO SAYS YES

The QC head and the owner

WHAT THEY ARE SHOWN

The deviation, the inspection results, and the customer’s written concession.

BEFORE

Sending a mould out for repair

WHO SAYS YES

The owner

WHAT THEY ARE SHOWN

Its history card, the repair quote, and the orders it is due to run.

Shot counts against maintenance intervals, beside rejection rates — each mould serviced before it makes scrap. Illustrative figures, drawn to show the working; not a customer’s records.

All departments of A PLASTIC PROCESSING UNIT on one dashboard

The same fourteen departments every OneSuite business runs on, in your trade’s words.

  • Machine OEE & Cycle Time via Retrofit IoT
  • Mould Life & Rejection Tracking
  • Order, Part & Job Booking
  • Production Scheduling & Shift Output
  • Resin, Masterbatch & Regrind Inventory
  • Mould Register, Maintenance & Changeover
  • Quality, Inspection & Sampling
  • Dispatch, Packing & Delivery Proof
  • Receivable Ageing & Collection
  • Power, Consumable & Maintenance Log
  • Accounting, GST & Financial Reporting
  • EPR / Pollution Compliance & Audit Trail
  • HR, Payroll & Shift Wages
  • Customer Support Desk

See it on one of your jobs

Send a job card, a week of shift reports and your last costing. We will show cost per part, OEE and the mould register as OneSuite would run them.

See it for my plant

Free for the first year.

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