In the rapidly evolving world of plastic injection molding, one challenge has become more prominent than ever before—an acute shortage of skilled processors. This shortage has placed significant pressure on manufacturers, leading to frequent process interruptions, excessive machine downtime, and an increase in scrap rates. The results? A drain on both time and resources, with skilled engineers tied up in troubleshooting rather than driving innovation.

As industries scramble to meet these mounting challenges, RJG has introduced a breakthrough solution: MAX, the Process Advisor. This AI-powered assistant, integrated into RJG’s CoPilot® process control system, is poised to revolutionize how manufacturers monitor, optimize, and troubleshoot their injection molding processes. By combining RJG’s renowned Master Molder® techniques with cutting-edge artificial intelligence, MAX empowers molders of all experience levels to tackle production challenges in real time.

Let’s dive deeper into how MAX is helping manufacturers optimize their operations, reduce scrap, minimize downtime, and enhance overall efficiency.

The Challenge: A Growing Skills Gap in Injection Molding  

Injection molding is a complex, highly technical process that requires precise control over a variety of parameters to ensure consistent quality. Traditionally, these processes were managed by seasoned technicians and engineers, whose experience allowed them to troubleshoot effectively and keep production running smoothly. However, as experienced operators retire and new talent is slow to fill the gap, manufacturers are left grappling with a significant skills deficit.

The impact of this shortage is evident on the plant floor. When injection molding processes go out of match, it can lead to poor-quality parts, wasted materials, and costly downtime as engineers work to diagnose and fix the issues. Additionally, operators lacking experience often make well-intentioned but misguided process adjustments that exacerbate the problem rather than solve it.

In short, the skills gap is leading to inefficient production, higher scrap rates, and wasted engineering hours.

The Solution: MAX, the AI-Powered Process Advisor  

Enter MAX, RJG’s latest innovation designed to address these exact challenges. MAX, short for Molding Automation Xperience, is an AI-powered assistant that acts as a knowledgeable expert on the plant floor. It monitors real-time process data, identifies issues, and offers immediate troubleshooting advice based on RJG’s decades of experience in process optimization.

MAX integrates seamlessly with RJG’s CoPilot system, which is already renowned for its ability to monitor and control injection molding processes. With the addition of MAX, CoPilot becomes even more powerful, offering real-time, step-by-step guidance that enables operators of any skill level to make informed decisions.

At the core of MAX’s functionality is its ability to provide actionable advice based on Decoupled Molding^® Principles. These principles are the backbone of RJG’s Master Molder training and have been proven to deliver reliable, repeatable results in even the most demanding production environments.

How MAX Works: Real-Time Troubleshooting at Your Fingertips  

So, how exactly does MAX work? Picture this: an operator notices that the machine is producing suspect parts, or the process seems to be out of match. Instead of waiting for an engineer to diagnose the issue, the operator can rely on MAX.

With a simple tap on the CoPilot interface, the operator can access the Process Advisor feature. MAX immediately gets to work, analyzing key process parameters—such as back pressure, screw RPM, and hold pressure—and guiding the operator through the necessary adjustments.

The process is simple and intuitive. MAX highlights the specific issues, offers detailed instructions, and waits for the system to stabilize before providing further recommendations. This step-by-step approach ensures that each adjustment is made precisely and that the process is restored to its optimal state without trial and error.

MAX also tracks all adjustments and actions taken, offering full transparency across shifts. This allows manufacturers to maintain a comprehensive audit trail for quality control, root cause analysis, and continuous improvement efforts.

Addressing the Skills Gap: Empowering All Operators  

One of MAX’s most transformative features is its ability to empower less-experienced operators. In an industry where the learning curve is steep, MAX provides a level of expertise that was once reserved for seasoned engineers. Now, even new operators can handle process issues confidently, thanks to the real-time guidance and expert advice that MAX offers.

This democratization of expertise is particularly valuable in an environment where finding skilled labor is becoming increasingly difficult. With MAX, manufacturers no longer have to rely solely on their most experienced staff to keep production running smoothly. Instead, operators at all levels can contribute to maintaining process stability, reducing downtime, and minimizing scrap.

Boosting Efficiency and Reducing Waste  

Efficiency is the lifeblood of any manufacturing operation, and MAX is designed to maximize it. By reducing the need for manual troubleshooting and minimizing the risk of human error, MAX helps molders maintain a higher level of process control. This leads to more consistent production, fewer rejected parts, and ultimately, less waste.

Moreover, MAX’s ability to retain suspect parts and offer insights into the root causes of process issues means that manufacturers can address problems proactively rather than reactively. This not only saves time but also helps reduce the likelihood of recurring issues that can drain resources over time.

Additionally, RJG’s CoPilot system—enhanced with MAX—offers robust data collection capabilities. Every action, adjustment, and process fluctuation is tracked and recorded, providing manufacturers with valuable data for ongoing process improvement and quality assurance.

Transitioning from eDART® to CoPilot®: A Seamless Upgrade  

For existing RJG customers using the eDART system, transitioning to the CoPilot system with MAX is a straightforward process. RJG has launched a time-limited buy-back initiative, allowing customers to trade in their eDART systems for credits toward CoPilot. This offers a unique opportunity for manufacturers to upgrade their process control capabilities while also gaining access to MAX’s AI-powered assistance.

The eDART Migration Tool is designed help eDART users quickly and easily convert eDART mold files and templates to be used on the CoPilot in production. The tool saves countless hours of manually re-entering data and ensures that there are no production delays waiting for converted files. It automatically converts the eDART files securely and accurately and stores them on the secure Hub until they are needed in Production. As needed in production, The Hub sends the mold configurations and templates to the CoPilot .

Conclusion: A New Era of Process Control with MAX  

As the injection molding industry faces increasing pressures—from the skills gap to the demand for higher efficiency—innovative solutions like MAX are more critical than ever. RJG’s AI-powered Process Advisor represents a new era in process control, where manufacturers can rely on intelligent, data-driven guidance to keep their operations running smoothly.

By combining decades of proven Master Molder expertise with advanced AI technology, MAX empowers molders to optimize their processes, reduce downtime, and minimize scrap. Whether it’s a seasoned engineer or a new operator on the plant floor, MAX offers the tools and insights needed to maintain peak performance.

In an industry where time is money and precision is paramount, MAX delivers the knowledge that manufacturers can trust.

Are you ready to take your injection molding processes to the next level? Contact RJG today to learn more about MAX and experience the future of process optimization.