Real-world validation of a modular digital architecture in plastic manufacturing SMEs

Abstract

This study proposes, implements, and validates a modular digital architecture tailored to small and medium-sized enterprises (SMEs) in the plastic manufacturing sector. The solution integrates complementary technologies, including thermal monitoring via Internet of Things (IoT) sensor networks, automated traceability using radio frequency identification (RFID), virtual simulation of production processes, and thermal optimization of molds through additive manufacturing with embedded cooling channels. The system was progressively deployed in real industrial environments following a non-disruptive approach, carefully adapted to the technical and organizational constraints of each participating company. The methodology involved an initial assessment, modular configuration, and evaluation using key performance indicators (KPIs). Quantifiable results include a 17% improvement in thermal stability, a 34.7% reduction in cycle time, elimination of component identification errors, and a 20% increase in overall operational efficiency. All implemented technologies achieved a return on investment (ROI) of less than 12 months. These results demonstrate the technical, economic, and organizational feasibility of adopting a modular architecture as a realistic and scalable strategy to drive digital transformation in SMEs.