Fuqiangxin: The Innovative Path of Intelligent Machinery and Smart Manufacturing

Image: Fu Chun Shin Precision Industry Co., Ltd. Chief Executive Officer Wang Junxian

Under the dual-axis drive of "Industry 4.0" and "carbon reduction targets," the injection molding industry is moving towards a deep transformation towards intelligence and greening. The overall trend focuses on digitalization, connectivity, and intelligence in production, striving to transform traditional factories into smart factories with self-regulation and decision-making capabilities. The overall trend in industrial technology development emphasizes the following developments:

Firstly, the injection molding machine and auxiliary equipment are connected through the Industrial Internet of Things (IIoT), becoming part of an integrated manufacturing system. Sensors installed on the equipment can collect key data in real-time, such as cavity pressure, energy consumption, output, and defect rates. Through AI and big data analysis, this enables transparent traceability, MES monitoring, and horizontal decision support.

Secondly, intelligent production lines facilitate vertical integration, connecting the entire process from order taking, scheduling, material supply, injection, post-processing, quality control to logistics on the same digital platform. The system is equipped with AI modules that optimize processes and quality, allowing managers to monitor the situation 24/7 and respond quickly.

Finally, predictive maintenance enhances overall efficiency by centrally monitoring and analyzing the status of injection molding machines, scheduling optimal maintenance times, and preventing simultaneous failures. In the future, scheduling can be dynamically adjusted based on delivery schedules and equipment health to ensure efficiency and stability.

Facing labor shortages, companies need to rely on digital and AI technologies to reduce dependence on manual experience and fill the technical workforce gap.

Fu Chun Shin's transformation goes beyond equipment upgrades, encompassing comprehensive innovations in system architecture, data integration, sensor applications, and AI algorithms, showcasing strong system integration capabilities. Through internal transformation and industry-academia collaboration, it has successfully developed the "iMF 4.0 Intelligent Manufacturing Platform," assisting clients in achieving data-driven smart factories.

The platform is divided into four core modules: Smart Machinery, Smart Peripherals, Smart Manufacturing, and Smart Management. Among them, "Smart Management" integrates MES, WMS, SRM, and other digital systems, serving as the central hub of the smart factory.

FCS injection molding machines are equipped with various sensors that can automatically detect melt viscosity variations using AI algorithms and perform parameter compensation to stabilize product quality, reducing machine adjustment time and cost. In the future, predictive diagnostics will be promoted to effectively prevent failures, enhance operation rates, and improve maintenance efficiency.

Injection molding machines are integrated with mold temperature controllers, material loaders, chillers, robotic arms, and other equipment through communication protocols such as Modbus, OPC UA, and EUROMAP 77, all managed by a central controller. A representative application is the "Intelligent Flow Balance Module," which can compensate for differences in melt flow rates between multiple cavities in real-time, enhancing filling uniformity and yield. The status of all equipment can also be monitored synchronously via the HMI, improving efficiency and speeding up troubleshooting.

This module integrates machine data and sensor signals to build a "product traceability system" and an "intelligent quality identification model." The former can record each cycle's process parameters, raw materials, environmental information, etc., to meet high traceability requirements. The latter establishes quality standards through feature comparison to automatically distinguish between good and defective products. It can also integrate with robotic arms to automatically remove defective items, achieving unmanned inspection and intelligent control.

Intelligent Management | Core Integration of Data Consolidation and Production Decision-Making OEE Management, through indicators such as availability, performance, and quality rate, to grasp the production line status and analyze bottlenecks. It features real-time work order dispatch, scheduling, anomaly analysis, trend monitoring, and remote decision support functions. In addition, FCS continues to expand the platform to encompass WMS, SRM, EMS, and EDI, creating an integrated smart factory.

FCS has established five factories in Taiwan, Dongguan, Ningbo, and Ahmedabad, India. In 2025, an application technology center will be established in Ningbo to strengthen regional support and showcase intelligent manufacturing. The number of connected machines has exceeded 1,000 units, and FCS actively participates in exhibitions such as Chinaplas in China and the K Show in Germany to present the latest achievements.

FCS developed a melt variation adaptive control system applied to the PP toolbox process, reducing weight variation from 6.65g to 2.97g and improving molding stability by 55%.

In terms of multi-cavity flow balance, the difference in melt flow rate of PP square container lids is reduced by 50% through sensors and hot runner compensation, enhancing consistency and efficiency.

The intelligent quality identification model achieved a 100% quality recognition rate using machine data under non-die cavity pressure sensors, applied to quality control of PCR polypropylene lunch boxes, demonstrating high accuracy.

After Taiwan Fan-Kang Enterprises implemented iMF 4.0, OEE increased by 9%, utilization rate improved by 7%, and efficiency rose by 5%. The annual profit per machine increased by 1.23 million yuan, and monthly capacity increased by 52 hours, significantly enhancing stability and order confidence.

Fuqiangxin is rooted in injection molding expertise and integrates software, sensors, cloud, and AI to build the iMF 4.0 platform, transforming into an "Intelligent Manufacturing Integrated Solutions Provider." In response to the waves of Industry 4.0 and ESG, FCS focuses on the platform as the core and technology as the driving force, creating a high-value-added, low-carbon, and scalable intelligent molding industry ecosystem to generate new value for global customers.