Smart Injection Molding for Automotive Suppliers: Achieve Greater Efficiency, Uptime, and ROI

ELK GROVE VILLAGE, IL, August 15, 2025 -

In today’s automotive manufacturing environment, operational efficiency is more than a competitive edge—it’s a necessity. Original Equipment Manufacturers (OEMs) are running leaner than ever, relying on just-in-time (JIT) inventory strategies that demand absolute reliability from their supplier networks. For Tier 1 and Tier 2 suppliers, this means production equipment must deliver higher output, better part quality, and fewer disruptions—all while supporting sustainability goals and shrinking margins.

Smart injection molding solutions are meeting that challenge. These advanced systems blend the speed and precision of all-electric machines with real-time monitoring, AI-driven control, and seamless integration across the manufacturing floor. 

For leading suppliers like Performance Gear Systems, Hoffer Plastics, and New Berlin Plastics, smart molding technologies from Shibaura Machine are helping achieve just that: faster cycles, less scrap, and higher uptime—all with a lower total cost of ownership.

The Efficiency Challenge: Why Traditional Systems Fall Short

Legacy servo-hydraulic injection molding machines, while reliable, present ongoing challenges for today’s automotive suppliers:

• Unplanned downtime from mechanical wear or overheating
• Extended cycle times that limit output
• High scrap rates from inconsistent process control
• Maintenance-heavy systems with long wait times for legacy components
• Labor-intensive adjustments that slow responsiveness

With OEMs operating on razor-thin inventory buffers and JIT strategies, even a short production delay can cascade into major disruption. Uptime isn’t just important—it’s mission critical.

Smarter Molding, Measurable Results

Smart injection molding solutions, particularly all-electric platforms like Shibaura Machine’s EC-SXIII series, are engineered to address these challenges head-on. They offer:

• Faster Cycle Times – Up to 10–15% increase in throughput vs. servo-hydraulic systems
• Minimal Maintenance – Fewer moving parts means less wear, no oil cleanup, and greater long-term reliability
• Lower Scrap Rates – Advanced servo-driven control enables better repeatability and tighter tolerances
• Reduced Energy Use – Up to 50% less energy consumption annually, supporting sustainability and cost-efficiency

In a recent whitepaper, a Shibaura Machine EC390SXIII all-electric machine produced Ford F-150 Lightning cup holders 3.2 seconds faster per cycle than a comparable servo-hydraulic unit. Over 4,000 operating hours, that added up to over $16,000 in annual productivity gains—not including energy savings, material waste reduction, or maintenance costs.

What Makes a Machine Smart?

Today’s “smart” injection molding systems go far beyond efficient hardware. They incorporate features like:

• IIoT connectivity via platforms like machiNetCloud, enabling real-time machine monitoring, diagnostics, and energy usage tracking
• AI-driven optimization, where the machine alerts for component variation or process drift—minimizing human error and labor dependency
• Advanced controllers like the V70, which support automotive-specific features such as customizable clamp sequences and natural pack settings for complex geometries
• Edge-to-enterprise integration, making it easier to connect molding operations with Enterprise Resource Planning (ERP), Manufacturing Execution (MES), and Quality Management (QMS) systems for complete traceability and workflow visibility

With machiNetCloud’s SUSTAIN App, automotive suppliers can even track Scope 1 and 2 emissions at the part level—an increasingly important metric for regulatory compliance and ESG reporting.

Solving Today’s Labor and Production Bottlenecks

Beyond mechanical performance, smart machines support workforce challenges in the automotive sector. With skilled labor shortages and training gaps, automated systems that  provide guided workflows help maintain consistent quality regardless of operator experience.

These machines also help prioritize plant resources. By leveraging IIoT data, supervisors can quickly identify where to focus maintenance or troubleshooting efforts—minimizing guesswork and accelerating response times.

Lightweighting and Advanced Process Control for EVs

As the shift toward electric vehicles accelerates, lightweighting has become a top priority. Smart injection molding plays a critical role in enabling complex, high-performance components that are both strong and lightweight.

Shibaura Machine’s Core Back Foam Molding process is one such example. Designed for automotive applications, it enables precise control over foam cell size, skin thickness, and hollow part structures—ideal for battery housings, interior trim, and structural components. 

Manufacturers benefit from:

• Significant part weight reduction
• Integrated complex internal features (like undercuts and hollow sections)
• Precision control to 0.01mm for repeatable, high-quality foam formation

By combining this process with the EC-SXIII platform and V70 Controller, molders can create next-generation EV parts with less material and lower energy consumption—without compromising structural integrity.

KPIs and ROI: What to Track and Expect

Smart molding solutions generate value across multiple operational KPIs, including:

• OEE (Overall Equipment Effectiveness)
• Energy cost per part
• Scrap and rework rates
• Cycle time reduction
• Maintenance hours per year
• Downtime incidents

In the whitepaper referenced above, the EC390SXIII machine total annual savings reached $26,924 per machine after factoring in energy, maintenance, material, and housekeeping costs. Most suppliers can expect meaningful ROI within 12–18 months—with compounding gains as additional machines are added or integrated.

The Road Ahead: Smarter, Cleaner, Faster

As we head toward K-2025, the future of smart injection molding is focused on connectivity, sustainability, and flexibility. Shibaura Machine is investing heavily in:

• Next-gen predictive diagnostics to further reduce downtime
• Closed-loop automation for quality control
• Eco-focused innovations to support circular material usage and energy efficiency
• Global service and support to ensure uptime—especially for North American automotive suppliers

Whether you're producing drivetrain components, interior assemblies, or lightweight EV enclosures, the right smart injection molding platform can transform your production line into a high-efficiency engine for growth.

Want to see what’s possible for your facility?
Schedule a customized productivity audit with Shibaura Machine to uncover where smart technology can unlock real value in your automotive manufacturing process.

Tel: (888) 593-1616

Email: im-success@shibaura-machine.com