Tosec is a metal company with approximately 100 employees based in Zwolle, in the Netherlands, which specialises entirely in sheet metal processing. Since 2011, SigmaNEST solutions have been used for the highly efficient nesting of metal panels and control of cutting machines in order to produce more efficiently and sustainably.
Two things stood out particularly in the benchmark and ultimately led to the purchase of SigmaNEST. One was the ease of use and the other the way in which it automatically nested quickly and efficiently.
TOSEC cuts, machines, bends and welds at one site, which guarantees short delivery times and high delivery reliability. The range of machinery is extensive and offers production possibilities for both small and very large items, from individual parts to mass production. Tosec does not focus on a single industry. Ruben Nieboer, General Manager at Tosec, summarizes his company's business activities: “We produce for many different customers from a wide range of industries. From mechanical engineering to offshore and heavy goods traffic to earthworks. Tosec is always able to carry out customized sheet metal processing."
Ruben Nieboer responds to the question of the biggest challenges that Tosec is currently facing in its industry: “Our focus is on producing as cost-effectively as possible and increasing automation to counteract the expected shortage of qualified personnel in the future, while continuing to deliver high-quality products on time.”
For example, with solutions from Teqram – a sister company of Tosec – more and more processes are being automated in production, such as material transport, the unloading of laser cutting machines and the grinding of oxyfuel-cut items.
In sheet metal processing, cutting naturally plays a central role. At Tosec, the machine shop is equipped with a comprehensive array of cutting machines.
SigmaNEST has been in use at Tosec since 2011. The focus of its application is automatic part nesting as well as programming of the cutting machines. These are wholly controlled using NC program code generated by machine-specific SigmaNEST postprocessors.
The software portfolio includes a total of three SigmaNEST Power Pack workstations, which are additionally equipped with 2x HD SuperNEST (see information box below) and a special bevel module. The latter supports programmers in the generation of knife, land and K bevels with fixed position and variable chamfers.
Since Tosec Solidworks is used as a CAD system for the preparation of incoming customer data, it was decided to add the Solidworks CAD Direct Import module to the standard interfaces. This allows direct access to the Solidworks part geometries and data.
HD SuperNest is a time-based nesting system that continuously nests parts. HD SuperNest calculates new nesting variants within a predetermined time interval until the yield can no longer be increased within the specified time interval. The breakdown is done through production planning.
For example, if the selected time interval is 30 seconds, SigmaNEST immediately creates a nest and then starts trying out other nest configurations. Each time the system finds better nesting within 30 seconds, the better nest is accepted, the timer is reset and SuperNest starts a new optimization run. This will continue until SuperNEST cannot produce a better nest within the time chosen. To shorten the total time that SuperNEST spends nesting, Tosec generally uses a 10-second interval.
When Tosec was looking for a software solution for the nesting of sheet metal parts and the control of the cutting machines at Tosec, the objective was clear. Software was needed which would achieve efficient material savings and simultaneously allow for the creation of cutting programs for machines from a wide range of manufacturers.
“SigmaNEST was already a market-renowned supplier in this area at the time, and that is why we included the solution in our choice of system. Two things stood out particularly in the benchmark and ultimately led to the purchase of SigmaNEST. One was the ease of use and the other was the way in which it automatically nested quickly and efficiently,” says Ruben Nieboer.
The base software from SigmaNEST could be implemented quickly and easily by TOSEC and was quickly put into operation following training. “Our employees did an excellent job in meeting the challenge of using new software and perfectly mastered it. Parallel to learning the new software solution, the SigmaNEST team worked with us to deliver the necessary postprocessors," recalls Ruben Nieboer. “We also placed great emphasis on the connection to our proprietary enterprise software, which we use for the generation of quotations to production monitoring to invoicing. We developed this connection ourselves and were fully supported by the SigmaNEST specialists.”
Marcel Schrijver, a long-time SigmaNEST user at Tosec and responsible for nesting, also speaks of challenges that needed to be overcome: “Chamfering on the plasma system gave us some headaches. After corresponding adjustments in the process, including changes to the postprocessor by SigmaNEST, we've largely got a grip on this now.”
Finally, the sheet metal processing specialists are unanimous in assessing the HD SuperNest algorithm: “We do not have exact figures regarding material savings. But we estimate that thanks to HD SuperNest, we were able to reduce our material consumption by an annual average of around 5% compared to the other SigmaNEST nesting algorithms.”
In the two screenshots provided by Tosec, the difference without and with the use of the HD SuperNest nesting algorithms can be clearly seen with the naked eye.
Finally, the conversation turns to the highly topical matter of sustainability and how TOSEC is addressing the challenge of sustainability within the company.
“We are increasingly noting that our customers are sensitive about this issue and require that we play our part. Our goal is, of course, to work as sustainably as possible. To achieve this, we must comply with all the rules on sustainability demanded by national and local legislation,” explains the Managing Director.
“Our material consumption of steel is immense and, of course, we generate corresponding quantities of metal scrap. We need to do more than merely recycle this material. Ideally, it is important to minimise the quantity of waste material in the interests of sustainability at the outset. The highly efficient nesting system that HD SuperNest provides helps us in this respect.”
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Tosec, a metal processing company in Zwolle, in the Netherlands, employs around 100 people and uses SigmaNEST solutions for efficient sheet metal processing and sustainable production.
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