Shops that remain competitive have one thing in common—the ability to adapt. And in an industry where every millimeter of sheet metal counts, the key lies in intelligent resource management. For manufacturers that have yet to implement a Manufacturing Execution System (MES) built for sheet metal operations, the real question is not whether they should—but how much they are losing by not having one.
More Than Software—A Strategic Planning Tool
MES solutions have been around for years, but most are not designed for the unique demands of sheet metal processing. They often lack precision and limit planning capabilities. A specialized MES, on the other hand, enables smart part grouping based on material type, thickness, machine type, sales order, customer, and delivery date—allowing shops to combine parts from different projects and reduce excess inventory.
But grouping parts is only half the battle. Material optimization is the real game-changer. This is where nesting algorithms come in—automatically determining the best way to arrange parts on a metal sheet to maximize material usage. Different shapes and sizes can be combined in a single job, ensuring minimal waste. If the sheet format changes, the new data is updated in the system in real time, ensuring full traceability and process consistency.
This level of integration goes beyond cutting. With a specialized MES, manufacturing and design codes are validated before production begins, reducing errors and eliminating costly mistakes. And for multi-site operations, solutions like Lantek Expert 2D CAD/CAM ensure that different teams have access to the same, up-to-date data, allowing a job to start in one country and finish in another without inconsistencies.
Simulating to Reduce Waste
Working with 3D geometries adds another layer of complexity. Without accurate simulation, a single miscalculation can lead to an entire sheet being scrapped—impacting multiple jobs at once. Being able to preview the design, part layout, and cutting process beforehand allows errors to be caught and corrected before production starts.
Flexibility is another critical factor. Operators should have the option to create nests manually or automatically, giving them greater control over production while ensuring adaptability to different job requirements.
A Well-Implemented MES: The Shop’s Central Memory
Production efficiency doesn’t stop at the cutting process. To achieve real optimization, an MES must act as the central intelligence system of the shop—collecting, organizing, and structuring key production data. This ensures consistency across multi-site operations and enables better strategic decision-making.
Think of a well-designed MES as the "banker" of production, storing and managing critical data such as:
This data-driven approach allows smart resource allocation and waste reduction. Instead of discarding unused material, a robust MES tracks remnants and makes them available for future jobs. Additionally, automated collision detection prevents cutting errors by adjusting lead-ins and adding micro-joints, ensuring minimal material loss.
Data-Driven Decision Making
If the MES is the banker, data is the currency. The ability to analyze production data is crucial to understanding real machine efficiency (OEE), measuring processed material versus finished parts, and anticipating stock shortages. Shops that leverage real-time analytics can optimize purchasing strategies—basing material orders on actual data instead of guesswork.
In an industry where waste directly impacts profitability, having a clear view of material usage, efficiency, and costs is a major competitive advantage. A specialized MES is not just about efficiency—it’s about profitability.
Not All Software is Created Equal
There are plenty of MES solutions on the market, but few are truly designed for the specific needs of sheet metal fabrication. Material waste is a real issue that requires purpose-built solutions. A robust MES does more than manage orders and production schedules—it captures and structures key data to provide real-time visibility into shop operations.
While manufacturers can’t control fluctuations in material prices, they can control how efficiently they use those materials. A specialized MES doesn’t just optimize production—it turns every millimeter of sheet metal into a well-managed investment.