Machines. Technologies. Materials.
Vol. 20 (2026), Issue 3, pg(s) 118-122

TECHNOLOGIES

A MES Application for OEE Improvement in Plastic Injection Facilities

  • 1 Department of Mechanical Engineering, Yildiz Technical University, Istanbul, Turkey
  • 2 Pleksan A.S., Istanbul, Turkey

Abstract

In plastic injection and plastic welding processes, the inability to accurately classify machine downtimes, the lack of visibility regarding performance discrepancies between shifts, and the reliance on largely manual methods for operator tracking hinder the sustainable improvement of Overall Equipment Effectiveness (OEE). Furthermore, the retention of pro- duction and energy consumption data in isolated systems complicates integrated performance evaluation.
In this study, the HBS MES system, developed by the in-house engineering team of Pleksan A.S. and fully integrated with HBS ERP, is examined within the scope of a field application aimed at real-time production tracking, performance analysis, and energy consumption reporting in plastic injection lines. As of 2025, HBS MES is actively used in its V1 version across three different plastic manufacturing enterprises; this paper exemplifies a facility predominantly focused on plastic injection.
The paper presents the system architecture, data collection logic, modeling of production and downtime events, the approach to calculating OEE and its sub-metrics, and user interface components in detail. As a result of the implementation in the studied facility, an improvement of approximately 25% in production quantities was reported, particularly during night shifts, and the mechanisms underlying this improvement are discussed. The findings demonstrate that MES solutions integrated with machine-embedded data collection modules can provide measurable productivity gains even in small and medium-sized enterprises.

Keywords

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