“SigmaNEST can evaluate and identify the sheet size that gives the best possible layout, in turn giving the best material efficiency.”
General Sales Manager
Siderurgica Simonato S.r.l. specializes in cutting flat sheets of various sizes, using different technologies and production systems. Siderurgica Simonato S.r.l. has recently computerized the internal processes of production and management through Gamma Lamiera. Gamma Lamiera is an ERP solution that integrates the work collaboration between SigmaTEK Italy and Nuovamacut Group that is now part of TeamSystem, one of the largest management software houses in Italy. Twenty years of experience and constant updating of technologies has proved Siderurgica Simonato to be a solid organization, capable of ensuring a broad and comprehensive service to solve any supply problems. Using processes such as oxyfuel, plasma and laser they are able to produce parts in various types of material and perform mechanical work and carpentry in addition to providing services such as sanding, deburring, smoothing, straightening, punching, bending, industrial painting, machining with chip removal and welding assembly.
Integrated Management of an ERP
The constant improvement of product quality is important: from initial acceptance, to testing the material through the various stages of processing and finally, inspecting before shipment. Particular attention is paid to customers’ needs through five strategic areas consisting of the technical staff, daily restock of the warehouse with plates of various qualities and thicknesses, large fleets of machines available, internal processing, and rapid delivery of the material provided by its own fleet of vehicles. Therefore, Simonato Siderurgica is a well-oiled machine, complex and articulate. Formerly, the company decided to computerize its internal management and production processes. In the early 2000′s Siderurgica Simonato began searching for an ERP solution to integrate their software solution, nesting and management. In 2002 SigmaNEST was found to be a perfect production system for the steel sector of Siderurgica Simonato, with its open infrastructure for customization and the ability to integrate management functionalities. However, the decision was put on hold as company growth did not leave an opening for implementation of new software. In 2006, the management control figures were negative and by 2007 the company finally concluded they needed the integration package that they previously researched, SigmaNEST. It offered a solution to meet the needs of time management tracking and estimates on material costs. Finally, in 2008 Siderurgica Simonato, took the leap to integrate SigmaNEST into their system.
One Database for Process Management Information
In understanding the production process of Siderurgica Simonato it is easy to understand the basis of their decision. First, the company works almost exclusively for third parties. This means that over 80% of their work are new items and are not replicated. These conditions make the company operate in a logical fashion. The flow of the production process is therefore composed of the following steps: creating a budget with entry-level ERP master data analysis of nesting, including sales order processing through MRP analysis, generation of production orders, production, storage and shipment. Previously, the organization’s internal information structure provided processes for nesting parts, accounting/administration and sales with a management system. The inventory management disturbed other activities with regards to planning, programming and production control. Typically these activities were done manually, paper-based or with office applications like MS Excel. Now the company is equipped with an integrated solution that allows a single database to manage all the information for all business processes. The administrative and accounting processes encompass planning, programming, and production control. This allows optimization on data entry and provides greater consistency in the flow of information in real-time. Today, the company is able to obtain timely and consistent information on each of the processes that go through without needing to check with various people. Gamma Lamiera is based on relational transactions in real-time in a single SQL database to allow all the data such as purchases of raw materials, estimates, work orders and statements to be available and constantly updated within the software.
The Procedure of Preventing Errors
The first step is to create a summary with Gamma Enterprise. At this stage, the creation of a new master data of parts, BOM and production cycles are necessary. SigmaNEST makes the process easy. The quote can be defined from a management point of view. If the quote is missing part geometry, it can be integrated directly into SigmaNEST by importing 2D CAD files (DWG, DXF,etc.) that read a format native to 3D geometry or you can easily and quickly draw 2D CAD using SigmaNEST. Once the parts are pulled into SigmaNEST within the quoting section, SigmaNEST will verify that the geometry is correct. Through the use of “AutoTask,” SigmaNEST will then automatically break the parts into separate nesting tasks based on the type and thickness of material, machine process then propose the best nesting algorithm for optimal and efficient nesting. Although the nesting process is automatic, SigmaNEST will give the user the option to edit and manipulate the nested parts. “A quote may contain various combinations of thickness and material,” explains Valter Bonelli, SigmaTEK General Sales Manager, “This often requires multiple nesting tasks for a complete analysis of the data.” SigmaNEST can help in the selection of the proper material size by using the “Use Best Sheet” option. Using this tool, several different sheet sizes can be selected so SigmaNEST can evaluate and identify the sheet size that gives the best possible layout, in turn giving the best material efficiency. Once the nesting engine is run, the quoted estimate is then validated by a Sales Manager and all information related to the nest is returned for the completion of a Gamma Enterprise Budget. The information received from SigmaNEST is used for budgeting updates in the master data. The bill of materials, remaining scrap, remnants, and cutting times are stored and used by manufacturing to calculate the estimated cost of production. The estimate returns to the sales department through Gamma Enterprise. The order is then processed by the planning MRP system, which results in a proposal for production and purchase. Once the order is received, the quote is converted into a work order and order is sent to the supplier.
Quality and Business Intelligence
The company ERP project involves the study and implementation of information through management processes related to quality and business intelligence. “The Gamma Enterprise solution includes the ability to expand into the world of quality and business intelligence using specific virtualizations natively integrated,” says Pier Luigi Ferrari, manufacturing manager of Nuovamacut. The company expects to manage quality control, along with problem solving returns, customer complaints, and maintenance through the implementation of the solution four. As a final phase, the company is expected to manage performance data through the creation of a dashboard of KPIs in real time, making available to the company management aggregate information necessary to make decisions based on objective data. This comes through the implementation of SigmaNEST.