The smart ProdACTIVE tool predicts the quality, energy and cost of the injection process in real-time, covering the 100% of products, and suggests the appropriate re-actions to adjust the process set-up and/or mechanism. It works in combination with the real time monitoring system (or Intelligent Sensor Network) to elaborate instantaneously the production data set with respect to quality/energy/cost prognosis. The client-server mechanism works in combination with the real time monitoring system (or Intelligent Sensor Network) to elaborate instantaneously the production data set with respect to quality/energy/cost prognosis. The client-server Connections, based on OPC_UA protocol that is accepted as Interface for Industry 4.0, are collecting all process data coming from all existing devices and active sensors in a centralized database.

A fundamental innovative characteristic of smart ProdACTIVE tool is the Cognitive predictive quality model integrating multi-resolution and multi-variate process data, monitored and gathered by an articulated network of sensors by means of the collection of distributed control system, advanced models linking process variables to specific defect generation mechanisms, new optimization tools and remote management of production by self-adaptive equipment. The final tool is a smart web application to visualize, share and communicate the significant data and to support the decision making with proper reactions in real-time (retrofit) based on the captured signals from the process and intelligent elaboration of data by the quality model.