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.

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

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.

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.

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!)

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.

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.

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.

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.

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.

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

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

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

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.

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.

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

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

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.

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.

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.

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.

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

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.

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.

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

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.

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

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