🏭 Industry · Plastics & Injection Moulding
Your moulding machines are running.
But what is the rejection rate on Mould #4 right now?
From material receipt to dispatch — live visibility across every moulding operation. Track shot counts, rejection reasons, mould performance, and assembly status without waiting for end-of-shift reports.
Plastics manufacturers — mould-wise rejection tracking live
As featured in PrintWeek India, April 2026
Your Production Flow
Every shot. Every rejection. Every mould tracked.
This is how a print job moves through your business. Clicarity gives you live visibility at every phase — and flags delays before they become client calls.
01
Order & Planning
4 stages
Order Received
Customer order confirmed — part number, material, quantity, colour, and deadline.
✓ Clicarity: Job ID created, mould assigned, material planned
Material Planning
Raw material grade, colour master batch, and additives specified per job.
⚠ ⚠ Common delay: wrong grade or colour — discovered only when first shots produced
Mould Setup & Allocation
Mould pulled from store, fitted on machine, and trial shots taken.
⚠ ⚠ Common delay: mould condition poor — maintenance required before production starts
Material Procurement
Granules, master batch, and additives procured or pulled from inventory.
✓ Clicarity: Material lot number recorded — traceability from granule to part
02
Pre-Production
3 stages
Material Drying
Hygroscopic materials dried in hopper dryer to required moisture content.
⚠ ⚠ Common delay: inadequate drying — splay defects in first production run
Machine Setup & Trial
Temperature, pressure, speed, and cooling parameters set and trialled.
✓ Clicarity: Setup parameters logged — reproducible for next run
First Article Inspection
First production parts inspected for dimensions, appearance, and function.
⚠ ⚠ Common delay: first article fails — parameter adjustment adds hours before production
03
Moulding Production
4 stages
Injection Moulding
Parts produced on injection moulding machine — shot by shot, cycle by cycle.
✓ Clicarity: Shot count, good parts, and rejections logged per shift per mould
In-Process Inspection
Sample parts pulled at regular intervals for dimensional and visual check.
✓ Clicarity: Rejection rate tracked live — spike alerts before full run is affected
Runner / Sprue Segregation
Runners and sprues segregated for regrind — regrind percentage tracked.
✓ Clicarity: Regrind quantity logged — excessive regrind flagged automatically
Packing & Counting
Good parts counted, packed in boxes, and labelled per customer requirement.
✓ Clicarity: Running count vs order quantity tracked — shortfall visible live
04
Secondary Operations
4 stages
Trimming / Degating
Gates, flash, and excess material trimmed from moulded parts.
⚠ ⚠ Common delay: excessive flash — mould maintenance required, delays assembly
Assembly
Moulded components assembled with other parts — inserts, screws, sub-assemblies.
⚠ ⚠ Common delay: one moulded component rejected — entire assembly batch held
Printing / Pad Printing
Text, logos, or markings pad printed on finished parts.
Ultrasonic Welding
Plastic parts welded using ultrasonic welding machine.
✓ Clicarity: Weld quality check logged per batch — failure rate tracked over time
05
Quality & Dispatch
3 stages
Final QC
Finished parts inspected for dimensions, appearance, function, and assembly fit.
✓ Clicarity: Final rejection rate by part number tracked across batches
Packing & Labelling
Parts packed in customer-specified packaging with part number and quantity labels.
✓ Clicarity: Packed quantity vs order confirmed before dispatch
Dispatch
Parts dispatched with delivery challan and inspection certificate.
✓ Clicarity: Full batch history — from material lot to dispatch — preserved
Where Plastics Manufacturers Lose Parts & Margin
Real bottlenecks. Real costs. Real fixes.
These are the patterns Clicarity helps plastics businesses identify and fix within the first few weeks.
Mould Performance
One mould running at 18% rejection — invisible in overall averages
A moulding unit tracked rejection rate by mould number instead of overall average. Mould #7 was running at 18.4% rejection while the overall floor average was 4.2% — masking the problem completely. Root cause: a worn cavity that nobody had flagged because the overall numbers looked acceptable. Mould repaired in week 2. Floor rejection rate dropped to 2.1%.
Floor rejection rate halved — single mould identified as root cause
Assembly Idle Time
Assembly team waiting 3 hours every morning for moulding to finish overnight run
Tracking production completion times showed that the overnight moulding run consistently finished 3 hours after the assembly team started their shift. Assembly operators were idle every morning — but moulding had capacity to start one hour earlier. Schedule adjusted. Assembly idle time eliminated. Output increased by 15%.
Assembly idle time eliminated — scheduling adjusted with data
Material Traceability
Customer complaint traced to wrong regrind percentage — 3 weeks to find cause
When a customer reported brittle parts, the manufacturer had no way to trace which material lot was used. Investigation took 3 weeks and involved testing multiple batches. With Clicarity, every job records the material lot number and regrind percentage used. The same investigation now takes 10 minutes — check the job record, find the lot, pull the material COA.
Customer complaint investigation time reduced from 3 weeks to 10 minutes
Real Printing Business. Real Results.
""Our rejection rate looked fine on the weekly report — 4.2% overall. But when we tracked it by mould, one mould was running at 18% rejection and dragging the average down. We would never have found it without stage-wise tracking.""
What improves in plastics businesses using Clicarity
↓ 65%
Rejection rate on flagged moulds
↑ 28%
Machine utilisation improvement
↓ 50%
Assembly stage idle time
5 days
To go live — full setup included
One licence. Your entire moulding floor.
No per-user fees. Full setup by the Clicarity team. Live in 5 days.
Single Licence
₹30,000
/ year
1 user · Annual licence
₹82 a day. Less than a daily meal for one person — for your entire team's visibility, all year.
Get a Quote
Multi Licence
₹55,000
/ year
Unlimited users · Annual licence
₹150 a day. Less than the cost of one missed delivery — for full visibility across your entire team.
Get a Quote
Annual billing · No hidden charges · Full setup included · Go live in 5 days
Questions from plastics businesses
How does Clicarity work for a printing business specifically?
Clicarity is configured around your specific print workflow — pre-press, printing, finishing, dispatch — in your terminology. Every job gets a unique ID and moves through your defined stages. You see live status, timestamps, and bottleneck alerts at every stage. The Clicarity team builds everything for you. You go live in 5 days.
Does it work for both offset and digital printing?
Yes. Clicarity works for any print process — offset, digital, wide format, screen printing, or a combination. The stages are configured around your actual workflow. If offset jobs go through plate making and digital jobs skip that stage, both can be tracked correctly under the same system.
Can it track material wastage at each stage?
Yes — with the Multi Licence. At every stage, your team logs quantity in and quantity out. Clicarity calculates the loss automatically. You see wastage by stage, by job, live — not at month-end when nothing can be done about it.
Will my press operators actually use it?
Yes. The update screen has two fields — Job ID and status. Under a minute. No training needed. GP Offset's entire team was using it from day one, including floor workers who had never used a software system before.
See every mould. Every rejection. While you can still act.
Book a free demo. We'll map your moulding workflow live on the call.
No commitment
Live in 5 days
Annual licence
Full setup included