TPO drives significant cost savings and increased productivity through process automation and optimization: Higher material utilization - reaching double digit material savings. Increased Router Productivity by 10%-30% through optimized cut-paths, increased cutting speed and reduced idle time. Reduced Work-in-Process (WIP) Inventory Enhanced agility to shorten Order-to-Delivery Time Automating routine manual tasks and eliminating associated errors. Solution Overview Plataine’s Total Production Optimization (TPO) solution for upholstery manufacturers, boat companies, other plywood cutting industries and panel products manufacturers, seamlessly bridges the gap between ERP/MRP, CAD and the production floor. TPO creates ready-to-cut production plans by retrieving critical information from both the ERP/MRP and CAD systems and optimally selecting the sheets to be used. Work orders, their due date and production quantities as well as sheet inventory information such as thickness and width & length are retrieved from the ERP/MRP while engineering data is retrieved from the CAD. TPO’s sophisticated algorithm then automatically produces a complete and optimized production plan, dynamically creating optimal nests. TPO supports multiple import and export formats, including: DXF, HPGL, NC Cut, Gerber, CATIA, Lectra (PLX, MDL), Fibersim and more. TPO Software is offered as a Service - SaaS - a fundamentally faster, less risky and more cost-effective alternative to ‘traditional’ (on premises) software installations. The SaaS model offers minimal upfront costs, faster time to value and ongoing payments that are closely coupled with the value received. Total Production Optimization (TPO) WoodOptimizer™ (formerly NESTERwood™) for The Upholstery & Boat Building Industries TPO bridges the gap between the Management, Engineering & Production TPO WoodOptimizer™ vs. Nesting Software Nesting Software TPO FabricOptimizer Role in organization Engineer- Level solution Enterprise level solution Input Parts & Geometry Parts & Geometry, Customer Orders, Available Inventory, Machine capabilities & availability Output Nest only Optimized Production plan Automation Nest only End-to-end process automation Optimization Nest only Integrated Optimization of all inputs Expected value Nest efficiency Total Production Optimization CAD ERP/MRP TPO WoodOptimizer TM Integrated Solution Complete Production Plan Customer orders & inventory Product design information TPO optimally decides WHICH Production order to run, WHEN, using WHICH sheet, on WHAT machine, WHILE creating the optimal nest A fully integrated end-to-end solution for optimizing plywood cutting through dynamic nesting and cut-path optimization. “We have seen a 17% to 18% increase in wood yield with WoodOptimizer” David Lewis, VP Upholstery Manufacturing, Drexel Heritage

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Page 1: Total Production Optimization (TPO) WoodOptimizer ... · information from both the ERP/MRP and CAD systems and optimally . selecting the sheets to be used. ... details and generating

TPO drives significant cost savings and increased productivity through process automation and optimization:

•Higher material utilization - reaching double digit material savings.

•Increased Router Productivity by 10%-30% through optimized cut-paths, increased cutting speed and reduced idle time.

•Reduced Work-in-Process (WIP) Inventory•Enhanced agility to shorten Order-to-Delivery Time•Automating routine manual tasks and eliminating

associated errors.

Solution Overview Plataine’s Total Production Optimization (TPO) solution for upholstery manufacturers, boat companies, other plywood cutting industries and panel products manufacturers, seamlessly bridges the gap between ERP/MRP, CAD and the production floor.TPO creates ready-to-cut production plans by retrieving critical information from both the ERP/MRP and CAD systems and optimally selecting the sheets to be used. Work orders, their due date and production quantities as well as sheet inventory information such as thickness and width & length are retrieved from the ERP/MRP while engineering data is retrieved from the CAD. TPO’s sophisticated algorithm then automatically produces a complete and optimized production plan, dynamically creating optimal nests. TPO supports multiple import and export formats, including: DXF, HPGL, NC Cut, Gerber, CATIA, Lectra (PLX, MDL), Fibersim and more. TPO Software is offered as a Service - SaaS - a fundamentally faster, less risky and more cost-effective alternative to ‘traditional’ (on premises) software installations. The SaaS model offers minimal upfront costs, faster time to value and ongoing payments that are closely coupled with the value received.

Total Production Optimization (TPO) WoodOptimizer™(formerly NESTERwood™) for The Upholstery & Boat Building Industries

TPO bridges the gap between the Management, Engineering & Production

TPO WoodOptimizer™ vs. Nesting Software

Nesting Software

TPO FabricOptimizer™

Role in organization

Engineer-Level solution

Enterprise level solution

InputParts & Geometry

Parts & Geometry, Customer Orders, Available Inventory, Machine capabilities & availability

Output Nest only Optimized Production plan

Automation Nest onlyEnd-to-end process automation

Optimization Nest onlyIntegrated Optimization of all inputs

Expected value

Nest efficiency

Total Production Optimization

CADERP/MRP

TPOWoodOptimizerTM

Integrated Solution

Complete Production Plan

Customer orders &inventory

Product design informationTPO optimally

decides WHICH Production order to run, WHEN, using WHICH sheet, on WHAT machine, WHILE creating the optimal nest

A fully integrated end-to-end solution for optimizing plywood cutting through dynamic nesting and cut-path optimization.

“We have seen a 17% to 18% increase in wood yield with WoodOptimizer”David Lewis, VP Upholstery Manufacturing,Drexel Heritage

Page 2: Total Production Optimization (TPO) WoodOptimizer ... · information from both the ERP/MRP and CAD systems and optimally . selecting the sheets to be used. ... details and generating

411 Waverley Oaks Rd, Suite 331, Waltham, MA, 02452 U.S. | Toll free: 1-866-500-5902 | [email protected] | www.plataine.com

© 2012 Plataine Ltd. | All Rights Reserved

“WoodOptimizer has provided Century with double-digit improvement in our nesting yields”Steve Bowman, CNC Programmer,Century Furniture

• Increase material utilization through best of class dynamic nesting: WoodOptimizer’s Optimization Servers continuously search for better nesting alternatives and identify the optimal solution for any given situation.

“We not only complete the work faster but also get more productivity out of our existing machines, which means that we can increase production without buying new equipment“Kevin Holshouser, Plant Manager, Lexington Home Brands

• Increase Machine Productivity: WoodOptimizer automatically integrates to all CNC machines and controller models and provides optimal tool-paths, highly efficient G-Codes, automatic multiple heads selection and more.

“We have no inventory of frame parts anymore; frames that are cut today are upholstered tomorrow”Mark Jordan, VP of Upholstery Operations,Bassett Furniture

•Support Cut-to-Order Operation: WoodOptimizer automates the entire production process by automatically receiving actual order details and generating ready-to-cut Production Orders for any given situation.

“TPO reduced plywood scrap by 60%, Work-In- Process (WIP) parts inventory by 90% and reduced labor numbers at Bernhardt”Larry Goad, Residential Upholstery Division Manager, Bernhardt Furniture

•Reduce Inventory Costs: Cut exactly what you need and when you need it. WoodOptimizer allows for true Just-In-Time manufacturing with no over-cuts, reduced WIP and less inventory handling labor.

Process Automation and Optimization

TPO WoodOptimizer™ is part of Plataine’s integrated Total Production Optimization (TPO) suite, targeted to specifically address the challenges of the Furniture, Upholstery and Boat Building Industries. Other TPO applications include: • TPO FabricOptimizer™: Plataine’s fully integrated end-to-end solution for fabric cutting, through dynamic nesting, roll-picking and cut-planning optimization.

• TPO FoamOptimizer™: A fully integrated solution for dynamic foam nesting, higher material utilization, better inventory management, and increased foam-cutter throughput.

• TPO Production Scheduler: Automatically and optimally assigns work to the appropriate work centers and machines, provides manufacturing information to shop-floor stations and collects progress reports in real time.

• Management Dashboards and Reports: Provides both floor supervisors and executives with a wide range of production metrics in real-time, including machine status, planned vs. actual progress, machine utilization and more.

ABOUT PLATAINEPlataine is a leading provider of production optimization software solutions for manufacturers of textile, metal, wood and composite material products. Plataine’s production optimization solutions enable manufacturers to be more competitive by increasing material utilization, improving productivity, and shortening manufacturing cycles to ensure on-time delivery of products to customers. Plataine’s customers include Ashley Furniture, Basset Furniture, Century Furniture, Ethan Allen, Flexsteel, Haworth, Interstate Foam & Supply, Lazar Furniture and Steelcase. For more information, please contact your local Plataine office or see www.plataine.com

Reduce Ecological Footprint without Compromising Productivity or Effciency: By one account, WoodOptimizer™ has so far saved over 50,000 trees and continues to save another tree approximately every 30 minutes.

“Utilizing WoodOptimizer’s RollingNest feature, an order that originally consumed 25 sheets of plywood was done using only 19 sheets”Shea Teague, Manufacturing Manager,Southern Furniture

•RollingNestTM: WoodOptimizer automatically creates a continuous cutting environment while orders stop/start within the same sheet. When a work order is generated, TPO optimally selects the best machining order to minimize waste and produces nests with both vertical and horizontal roll-overs between styles.

Sheet 1 Sheet 3 Sheet 4Sheet 2

Kit 1 Kit 2 Kit 2 Kit 4

Kit 3

Kit 1