Our solutions help reduce steel consumption at various stages of production. When you consider the price of steel, your company's scrap rates, and the number of tons produced each year, calculating the potential savings is straightforward. These savings represent a significant opportunity for improvement, especially in an industry where steel fabricators have relatively few options for reducing costs and improving profit margins.
First, our bar nesting and plate nesting algorithms significantly reduce material waste. During production preparation, they optimize the arrangement of parts within the bars and plates purchased from your suppliers to maximize material utilization. Thanks to our advanced machine integration, these algorithms take into account the specific capabilities and characteristics of each machine, allowing for even greater optimization of steel usage. For example, in plate nesting, the algorithm arranges parts to enable common-line cutting whenever the machine supports it. In addition to reducing material waste by minimizing the remaining skeleton, this also optimizes machining times. Similarly, for bar nesting, the algorithm can nest two haunches together to save steel while also reducing production time, since a single cut can be used for two parts. Ultimately, savings on consumables can also become significant.
Second, our solutions help prevent errors throughout the entire production process. For example, all parts scheduled for production are automatically checked before being released to the shop floor. Programs are generated automatically, eliminating potential operator errors associated with manual programming directly at the CNC controller. In addition, several features help prevent errors at manual workstations. For example, scribing identifies the positions of secondary components on main structural members. Since this information is automatically marked on the parts by CNC machines, there is no longer any need to manually locate the components during assembly, reducing the risk of human error. Considering that any incorrectly manufactured parts may ultimately need to be scrapped, the importance of a reliable production process becomes clear. Beyond reducing errors, all the benefits mentioned above also generate considerable time savings, helping ensure that delivery deadlines are met.
The numerous analyses and customizable reports available in Steel Projects PLM provide comprehensive visibility into project management and production data, making it easy to measure gains and losses.