Welcome to the CoPilot Database!

Installation Guide, FAQs, and More Information About CoPilot

Whether you’re a new CoPilot user looking for installation instructions, a veteran with an operation question, or doing your research before committing to the CoPilot, you found the right place!

To start, let’s skip to the stuff that matters to you: What best describes you?

I am here to learn more about CoPilot
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About CoPilot

CoPilot is the latest in injection molding smart technology. This simple, user-friendly software makes it easier than ever to ensure your customers receive only the highest quality parts while minimizing waste, optimizing efficiency, and bridging the skills gap.

An Overview of CoPilot

CoPilot solves ongoing injection molding challenges including: 
  1. Slow troubleshooting time, guess and check work
  2. Untrained staff aren’t able to resolve problems without a process engineer
  3. Shipping suspect parts
  4. Not knowing what changed in a process
  5. Excess scrap, machine downtime, and lack of visibility in the process
  6. Inconsistent processes due to inefficiencies and human error
 CoPilot features include: 
  1. Brand new AI technology that walks you through how to fix your process, so anyone can start making good parts again fast, despite their experience level
  2. Real-time, on-screen notifications when a machine is down or producing suspect parts
  3. Set up alarm limits and templates for process matching
  4. View data from each shot
  5. Automatically retain suspect parts and understand what happened in the process
  6. Total part and process audit records
  7. Process automation
Watch a brief demo of CoPilot:
CoPilot is Now Equipped with AI!

Meet MAX, the Process Advisor®. Molding Automation Xperience (MAX) features an intuitive and easy-to-use interface that provides step-by-step advice to help you restore your process to optimal performance. This smart AI, powered by proven Master Molder® techniques, delivers you with an unparalleled level of control, efficiency, and quality never before possible.

CoPilot Installation Guide

In this guide, we define who is responsible for each step of the process, so you can focus on only what matters to you—”User” refers to the personnel who will be using CoPilot the most. Click on each section to expand it and get the tools needed to complete that step.

If you have any questions along the way, your RJG point of contact will always be here to help!

Step 1: Ensure presses are ready for installation  (Maintenance, RJG)

This step should already be complete by now, but if it’s not, now’s the time to ensure that your presses are ready for CoPilot installation. This will require assistance from your maintenance crew as well as RJG. We will ensure the appropriate injection molding machine signals are available to make installation as efficient as possible.

Tools Needed:

Copilot Hardware Installation & Setup Guide: Review page 40 for a complete list of required signals and corresponding terminology

*Must have – Injection Forward, Second Stage, Screw Run, and Mold Clamped

Step 2: Make sure IT is on the same page (User, IT, RJG)

We will meet with your IT department to ensure they are fully informed and on board with the implementation prior to installation. This will ensure they have the tools they need up front, and we can address any potential roadblocks right away.

Tools Needed:

The Hub Software Virtual Appliance (VA) Product Manual

Step 3: Make sure The Hub is properly installed (RJG, IT)

It’s vital to ensure that The Hub is installed in order to network CoPilot systems together. RJG will work alongside your IT team to ensure this is done properly and that everything meets your IT and security requirements.

Tools Needed:

The Hub Software Virtual Appliance (VA) Product Manual
Software Specifications – Page 15
Installations Requirements – Page 17
Installation Process – Pages 18-37

Step 4: Complete Copilot & The Hub software networking checklist (IT)

Once you have an understanding of how the software works, complete the Hardware Installation and Setup Guide below, either on your own or with an RJG professional. It’s important to follow each of these steps to ensure accuracy and maximum effectiveness of your CoPilot system.

Tools Needed:

Copilot Hardware Installation & Setup Guide Page 73

Step 5: Schedule Copilot Takeoff Training  (User, RJG)

Congratulations, installation is complete! Now it’s time to schedule your CoPilot Takeoff Training. Work with your RJG professional to schedule a time that works for your team to have one of our experts come to your facility and train them on how to properly and effectively utilize CoPilot. This is a vital step that ensures your success and employee confidence in the technology. We like to get things on the schedule early, as we know calendars fill up quickly, and it can be difficult to find a time that works for everyone.

While you wait to complete your Takeoff Training, we suggest completing the FREE, 1-hour, self-paced Meet Your CoPilot course here. 

Step 6: Create user names and passwords on The Hub (User)

This may seem like a simple step, however creating new users, passwords, and associated permissions will be paramount to ensuring data security, traceability, data integrity, and user accountability.

Tools Needed:

The Hub Software User Guide: Pages 79-84 (Includes role permissions)

Step 7: Confirm hardware installation strategy (Maintenance)

As with any new technology implementations, it is vital to have a clear understanding of the components involved. Ensuring that you are following the recommended steps and precautions will mitigate any risks or functionality issues down the road. A well-planned installation simply leads to a more efficient and enjoyable technology adoption process.

Tools Needed:

Copilot Hardware Installation & Setup Guide: Pages 15-21

Step 8: Complete installation checklist (Maintenance)

Ensuring an efficient and optimal installation of your RJG technology will ensure ongoing success, both for your business and your team. This document will serve as your Standard Operating Procedure for all installations moving forward, allowing for full confidence in each installation and mitigating any future risk.

Tools Needed:

Copilot Hardware Installation & Setup Guide:
CoPilot System Hardware Installation Checklist on pages 53-61
ID7 Module Wiring Diagram on pages 22-23

Step 9: Complete CoPilot system machine sensor & module configuration checklist (Maintenance)

Once you have completed the Copilot System hardware Installation Checklist, it’s time to verify everything is functioning properly. Use this tool to verify the installation and function of machine-mounted sensors and modules for use with CoPilot.

Tools Needed:

Copilot Hardware Installation & Setup Guide: Pages 63-68

Step 10: Complete Copilot system mold sensor configuration checklist (if using cavity pressure sensors) (Maintenance)

We have finally arrived at the last step of installation! If you are utilizing RJG cavity pressure sensors, you know how vital they are to your everyday production, so let’s make sure they are doing their job! This section will also touch on CoPilot software configuration, process alarm configuration, process templates, and V-P transfer configuration. As always, if RJG can assist your team in any way throughout the installation process, we are ready!

Tools Needed:

Copilot Hardware Installation & Setup Guide: Pages 69-72

Step 11: Complete Copilot Takeoff Training  (User, RJG)

Now that everything is set up, it’s time to get your team on the floor and do some hands-on training. This is a two-day course consisting of basic utilization training, practical exercises, and applications that allow you to put to practice what you learn and ask case-specific questions. CoPilot Training can take place at your facility, our facility, or online. The online course is only one day, then the practical exercise is carried out at a later date, either at our facility or yours.

To prepare for takeoff, here are a couple resources you may want to review prior to training:

Meet Your CoPilot Online Course

CoPilot User Guide

Step 12: Ensure system is up to date (User)

It’s just about go time, we just need to make sure you’re using the most up-to-date version of the software before takeoff! As a best practice, we recommend you designate one individual to lead the system update process as the updates are released by RJG.

 You can download future updates on our website here.

Step 13: Takeoff! 

Congratulations, you completed your CoPilot onboarding and installation!! Now it’s time to watch the magic happen. If you have any questions along the way, we’re always here to help.

Thank you for allowing us to help you mold smart!

Frequently Asked Questions: 

How does CoPilot compare to competition?

CoPilot is the most user-friendly platform in the industry today. It is so easy to use, untrained staff can quickly understand what’s happening in the process and fix it without the need of assistance. CoPilot is also now powered by AI, MAX the process advisor, which is the first of its kind. MAX uses proven Master Molder® techniques to not only tell you what went wrong in the process, but to walk you through how to return your process to its set template.

How often will you have major updates/additions to CoPilot?

You can expect roughly 2–4 major updates a year, but we are regularly updating and maintaining the software.

Do I have to have The Hub if I have CoPilots?

YES. Copilot is NOT meant to store more than two weeks of data. The true power of the system resides in The Hub, because as you know… data is king! The Hub is required, because it manages all of the logins/security, permissions, historical data, and updates for your CoPilots—like a central system. CoPilot and The Hub work together to create facility or organizational wide value rather than focusing on a single machine or job. You can have up to 200 CoPilot systems in a single facility connected to The Hub.

Do I have to purchase/complete the CoPilot Takeoff Training?

Yes, to ensure that you are receiving maximum value and return on your investment into RJG technology, training is a must. We want every part of your relationship with RJG to be as positive and beneficial as possible, we are truly in this together.

We already have eDARTs and the EDM, why should we get CoPilot?

Investing in technology is a business decision, and marketing your business with the latest and greatest is a huge advantage for you. The eDART® System can operate over time if you are not ready to fully invest, but we can transition new programs as they come in so you can continue to lead the industry with the latest technology and make data-driven decisions. In addition to that, we will be pouring our resources into CoPilot moving forward, including maximizing AI to create a seamless, profitable experience for you. (Check out this blog post on why you should upgrade now!)

It seems expensive… how much does it cost to implement?

The actual cost varies from project to project depending on the number of machines and your specific needs, but it is comparable to eDART and also includes training and The Hub. The ROI, though, is massive, and if harnessed properly, it can pay for itself within a year of implementation. From reducing your machine downtime to increasing production rates and cutting scrap (not to mention not shipping anymore bad parts to customers), we have seen huge payouts. Just imagine how much you will save just by cutting your scrap and downtime in half.

What if we don’t have the time or resources to test out new technology?

Don’t fret, we’re here to help! Our experts will be right alongside you holding your hand the entire time. It’s a bit of a time commitment up front, but we promise you that the saved time later more than makes up for it! Imagine not having to sort parts, put out fires, or figure out what happened last night… every morning shift. Investing that time into implementing new technology that will combat those challenges (and more) will result in huge payoffs and allow you to focus your efforts in more productive ways than fighting fires.

What if our team isn’t knowledgeable enough to understand how to use it?

CoPilot boasts a user-friendly, simple interface that even untrained staff can navigate. Beyond that, we will be by your side, getting your team up to speed and ensuring you get the most out of your investment, including hands-on training with one of our experts.

We have our own method for tracking things… why do we need technology to do it for us?

Often, we build tools to fill needs as they arise, but those tools aren’t always the most efficient. They’re often cobbled together and require ongoing manual work that becomes cumbersome and leaves holes in our ability to track things. By implementing new technology to do that hard, time-consuming work for you, you no longer have to rely on the manual inputs and run the risk of human error. You can access data from anywhere in the world and prove out every part you ship through automated reports. No more manual tracking, no more manual audits, and no more worrying about liability.

CoPilot MAX AI – Frequently Asked Questions: 

Is MAX a paid add-on? Is there a license?

Yes, there is a license key required for MAX. Currently, there is not an extra fee for installing and using MAX. This may change in the future.

How is the license key installed?

RJG Engineering or RJG customer support will need to install the license key using a remote connection.

What information does MAX use for Template Match?

  1. Template Match for MAX is determined by the End of Cavity Pressure Template.
  2. MAX does not use the alarm settings to determine the in or out of match state

What if there are more than one End of Cavity Templates?

Template Match for MAX is determined by the End of Cavity Template that is the furthest out of match.

Does MAX use Post Gate or Mid Cavity Pressure Templates?

MAX does not use Post Gate or Mid Cavity Pressure Templates initiating advice. However, the Template Match Indicators will turn “Yellow” or “Red” if a Post Gate or Mid Cavity Pressure is out of match.

What is the basis of the logic for MAX advice?

MAX’s logic is based on Master Molder process development and troubleshooting methods. MAX begins with Melt Preparation, i.e. Back Pressure. MAX then matches the Cavity Fill. Once Cavity Fill is matched, MAX then matches Cavity Pack. Finally, once Cavity Fill and Pack are matched, MAX matches Cavity Cooling Rate.

Can MAX be used with a Decouple III process?

No, if V-P is assigned or in use on the CoPilot, MAX advice will be prevented from starting.

Can MAX be disabled for certain processes or molds?

Yes, MAX can be enabled or disabled for each individual mold and process.

How is MAX set up or configured?

There are two steps:

  1. The user can set the match and out of match percentages for Mold, Machine and Material on the Template Match Setup card. The percentages default to the percentages taught in Master Molder and can be edited by the user.
  2. The user then needs to establish the normal variation range on the Template Match Dashboard card. This is crucial in order to reduce false out of match indications. The number of shots used to generate the normal range defaults to 20, however this may need to be changed based on normal process variation.

What if I don’t set good normal variation ranges?

There will be an increased chance of receiving false out of match indicators. The ranges can be reset by the Process Engineer if this becomes problematic.

What events cause the safety check messages?

The safety check messages are triggered by the following events:

  1. If less than 50% of the cavities are out of match.
  2. If the balance between cavities is below 90% and is outside the normal variation by greater than 20%.
  3. If the Material Viscosity shifts by more than 20%.
  4. If Velocity to Pressure Transfer is enabled or in use.
  5. If the peak cavity pressure increases to 10% above the templates peak cavity pressure.

Why does less then 50% of the cavities out of match cause a safety message?

If most of the cavities are not affected, there is a risk that process changes to match those cavities will cause other cavities to go out of match. Or in the worst case scenario when making process changes to match the out of match cavities could cause other cavities to flash.

Why does cavity imbalance cause a safety message?

There is a risk of flashing the cavities that fill earlier in the process while making process changes to get the cavities in match.

Why does exceeding 20% material viscosity shift cause a safety check?

Often times, drastic changes to the process need to be made to match the cavity templates when the material changes that significantly. Making such drastic changes to the process is better determined by a processing expert.

Why does using velocity to pressure transfer cause a safety check?

Decoupled III process can be complex. Those processes normally do not need adjustment unless something major occurs. Evaluating the cause and the correct adjustments are better determined by a process expert. This was confirmed by our industry research and process experts.

Why does MAX produce a safety check error if the current peak cavity pressure is 10% higher than the templates peak cavity pressure?

Increasing the cavity pressure significantly above the cavity pressure template value can cause the mold to flash.

Why does MAX stop advice and have no recommendations?

  1. If cooling rate is still out after the general checks and after cavity fill and pack are matched.
  2. If the End of Cavity template is matched but the Post Gate or Mid Cavity templates remain out of match.
  3. If the End of Cavity template is matched and the Machine template remains out of match.

How does RJG troubleshoot MAX?

The user will generate an error report and send it to RJG Customer Support.

Will MAX be improved?

Yes. MAX will continue to improve. The Product Team continues to gather feedback from users and RJG experts to determine the MAX roadmap.

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