Augos Factory / Industries / Packaging and plastics
Packaging, plastics and converting plants in South Africa
On one line, 3,175 of 3,334 stops in a week were short.
Injection presses, blow moulders, printers, slitters and wrappers lose time in stops too short to write down. A jam, a blocked chute, a reel that needs a nudge. Augos Factory times every one, so the line, the shift and the maintenance team each see the stops they can recover.
One week on one line
The stops nobody logs add up fastest
Of 38.6 hours lost to stops in the week, 14.8 hours came from interruptions. The plant had set up its stop reasons down to station level, so the record could show that one station alone stopped 49 times for 7.0 hours. One fault repeated 18 times, for 2.6 hours: one for maintenance to fix at the root.
Research: interruptions on South African lines ›
Case studies from food packing, building materials and processing plants ›
One week of stops on one line
MeasuredAugos platform, Downtime Report · one anonymised line · one week in 2026 · site, products and people removed.
Where packaging and plastics lines lose time
Four losses this industry knows well
Mould and tool changes
Each change timed against its allocated time, with the team's fastest change shown.
Cycle time drift
The sensor counts every cycle. Actual cycles run against the rated speed set for each product on each press, shown as speed loss by product and by press.
Reel and film changes
Recorded as planned stops, so a slow splice shows as overrun, not as "downtime".
Jams and interruptions
Counted by the sensor without an operator code, then grouped by station and time of day.
Quality at the line
Rejects against the job, not the month
Operators enter the reject count at the Augos Operator Terminal against the job that made them. Rejects and stops are recorded against the same job. A run with many stops and many rejects shows up together, so you can look for one cause instead of chasing two.
Rejects carry no reason code. When a quality problem stops the line, that stop gets a reason like any other.
Stop time beside reject rate, one press
IllustrativeOne injection-moulding job, 8 hours: 9,600 made, 384 rejected, yield 96.0%.
Last ten jobs on the same press, ranked by stop time
The jobs that stopped most also rejected most. With both on the same job, the press team works on them as one problem.
Illustrative data, not a customer.
Questions
Packaging and plastics, answered
Where does the sensor go on a moulding line?
On the bottleneck, usually the press or the downstream packer, where it sees every cycle and every stop. We agree the spot with your engineer on site.
We run many presses. Is it priced per press?
Priced per line, and each press with its own sensor and terminal counts as one line.
Do we have to connect to our machines' controllers?
No. Nothing is read from your PLCs or SCADA. One sensor and one terminal per line.
See every interruption on a line like yours.
Thirty minutes with a manufacturing specialist, on a week of stops from one line, short ones included.
- Every stop timestamped
- Grouped by station and shift
- Prices in rand, ex VAT
A manufacturing specialist replies within two business hours to set a 30-minute call.