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Case Study

 

Case Study EUSIDER SPA using Coil Cut Optimizer

 
 - Trim-Loss (Scrap) Reduction by 20%
 - Time to generate Cutting Programs Reduction by 40%
 

 

Eusider Company Profile

Eusider was set-up in 1979 as a Steel Service Centre dedicated to Steel distribution. Three generations of Anghileri’s have built this fully-family owned company specialized in the metal industry, which has made Eusider grow fast and steadily. Eusider has a wide customer base that includes small-, medium- and large-size companies using steel. Eusider offers each of them transparent trade relationships, a wide range of products, certified quality, highly flexible deliveries, an efficient service and highly competitive prices. The Eusider group includes: Metaltubi, Lima and IronService.

Eusider context and challenge

 

Eusider Group has had a significant grow during last few years, arriving to a yearly delivery of 400'000 tons, a revenue of 220 million Euro and 130 employees. The fast grow has required a transformation in the organization and in the information system. This transformation includes the implementation of the world wide leading ERP SAP, the introduction of QR Codes to facilitate Store management and Coil Cut Optimizer in order to improve the efficiency of Programming department and to reduce Trim-Loss in Production.

Coil Cut Optimizer solution

 

Coil Cut Optimizer (CCO) is an Optimization software developed by Fast-Square, specifically for Steel Service Centers. CCO respects all Customer Order constrains and the Cutting Machines specification during the Optimized Cutting Programs generation. The CCO User Interface has permitted also the persons without much experience to generate Optimized Cutting Programs after few weeks. The utilization of CCO has also helped with the data cleansing of Customer Orders and Coils.

Results

 

Before the introduction of Coil Cut Optimizer, the Programming

department had 10 persons working 50% of the time generating

Cutting Programs. With CCO usage, Eusider has reorganized the

Programming department with only 3 full-time Programmers, with

two of them recently hired and without Programming experience.

So there has been a reduction of time dedicated to generate

Cutting Programs by about 40%, even with the lower experience

of the new employees.

After two month of continuous usage of CCO the number of late

programmed Orders has been reduced.

The Trim-Loss company Target for Cutting Programs on Slitting

Machines was 1.50% and during last weeks before CCO usage it

has been about 1.55%. As shown in the graph, in few weeks the

Average Weekly Trim-Loss has been stable between 1.25% and

1.35%, with a reduction of about 20% of Trim-Loss.

 
 

Case Study Sanitary Paper Mimosa - Lebanon

- Scrap Reduction by 27% for Paper Indusry Customer

Customer Profile

​Sanitary Paper Mimosa Co. is based in Kaa El Rim, Lebanon and is involved in the production and marketing of Tissues Paper Products, Carton Corrugated Boards, Craft Cardboards, printed cardboards boxes for industrial and agricultural.

The company produces also recycled papers and cardboards for various industries.

CCO-Paper software to optimize Corrugated Cardboard Machine

Sanitary Paper Mimosa has asked Fast-Square to optimize the planning and cutting of the Corrugated Cardboard Machine, minimizing Trim-Loss (Scrap).

These machines have different phases: Pre-heater, Soldering, Drying and Cutting.

The Cutting phase is divided into two stages: Slitting of Mother Roll and Cut-To-Length with the constraint of maximum two different length.

The objective of CCO-Paper software is to optimize the Cutting Phase in order to minimize Scrap in the two dimensions of width and length.
Customer Orders can have different shape, like sheets, die, boxes, trays.

CCO-Paper calculates the actual dimensions to be cut in width and length, in order to construct the final object, requested by the customer.

Benefits

With the first CCO-Paper prototype, we have realized the potential benefits of the software.

We tested the software with a real full day production plan of the machine. We succeeded in saving more than 2000 Kg of paper just on one day of Production, using CCO-Paper.

The calculate yearly potential benefit is a saving of over 480’000 Kg of Paper.

The Scrap reduction has been 27% compared to the original production plan.

 

Gino Giannone CEO Fast-Square:

Sanitary Paper Mimosa has given us the opportunity to enter in the Paper Industry market,

which seems to have huge saving opportunities.

We would like to continue to develop our software solution with other Customers in this Industry.

 

Case Study ARVEDI Group 

- Cut Optimizer in Acciaieria Arvedi
- Cut Optimizer and Scheduler in Centro Siderurgico Adriatico
- Cut Optimizer and Scheduler in Centro Siderurgico Industriale

10 Years long relationship with Acciaieria Arvedi

Acciaieria Arvedi has been one of the first Steel Industry Customers, using Coil Cut Optimizer software since more than a decade.

The collaboration has continued with the implementation of CCO-Cut-Optimizer and CCO-Scheduling at Centro Siderurgico Adriatico (previously Metal Castello) with GO-LIVE during 2017 and the recent signature of two new projects with Centro Siderurgico Industriale in Perugia.

Acciaieria Arvedi is using Fast-Square software CCO-Cut-Optimizer since 2008. CCO software started to support the generation of Optimized Cutting-Plans of Service Centers of Cremona and Corbetta since 2008, while later Arvedi has extended the use of CCO software also to plan the cutting of Steel produced in Trieste plant.

 

“CCO has helped us to reduce trim-loss further during coils cutting process in our plants,

increasing also the effectiveness of our programmers of the slitting machines. We have

appreciated the technical and project design competence of Fast-Square consultant

and their availability.”

Ing. Gianni Lauritano /  IT Director Acciaieria Arvedi

LIVE projects in Centro Siderurgico Adriatico

In 2016 Arvedi Group took over Centro Siderurgico Adriatico Steel Service Center and decided to improve the Supply Chain and ERP software.

In few months Fast-Square has completed the CCO-Cut-Optimizer project, improving the Optimization and control on the process of generation of Cutting-Programs. After the very good collaboration during this first project, CEO Cristian Marchetti has asked Fast-Square to develop also a Scheduling Tool specific for Steel Service Centers, integrated with Cutting-Plan generation and the company ERP. Since September-2017 CCO-Scheduling is LIVE, with capacity constraint scheduling, considering Work-Order dependency and including a Graphic User Interface for manual changes to the Schedule. The Software includes a Promise-Date module for Commercial Users, showing the real time status and Availability Date of all Customer-Orders.

“The quality of the collaboration with Fast-Square can be summarized in ‘Professional

Partnership which advices the Organization to reach Continuous Improvement’ “.

Roberto Rocchegiani / Managing Director Centro Siderurgico Adriatico

New Contract in Centro Siderurgico Industriale and Further development

 

Another Steel Service Center of Arvedi Group, Centro Siderurgico Industriale (CSI) has signed the contract to implement CCO-Cut-Optimizer and CCO-Scheduling in its Perugia Plant, while discussions are on-going for the implementation of CCO-Replenishment for Demand Planning and Coils Purchasing re-order in CS Adriatico.

 

“We have a very good collaboration with Centro Siderurgico and Arvedi Group.

They are demanding Customers who stimulate our organization to find and develop new solutions

to improve the effectiveness and productivity of our Customers”.

Gino Giannone / CEO Fast-Square

Case Study MARCORA S.p.A.

- 20 years long collaboration with Fast-Square
- CCO Complete Supply Chain Solution
- Production Efficency improvement

Customer Profile

The industrial activities of the Marcora family were born in the second post-war period thanks to the initiative of Giovanni and Andrea Marcora. In 1954 Andrea created a commercial and service activity in the steel sheet sector. Today Marcora S.p.A. is one of the main Italian operators in the pre-processing and sale of flat thin carbon steel.

The industrial activity is carried out on a covered area of ​​24’400 square meters and total area of 50’000 square meters. Currently Marcora has two production sites in Inveruno (MI) and Cuggiono (MI), with 11 cutting-lines (Slitters and Cut-to-Length), capable to generate a maximum annual production capacity of 300,000 Tons.

 

20 Years Joined Development

 

Marcora has been one of the first Customers of Fast-Square, developing together the first version of CCO-Optimizer. The long-time collaboration has helped to develop continuously new software modules, specific for Steel Service Centers.

Marcora has started to use the very first version of CCO-Optimizer since 1997 and during recent years has chosen to cover its whole Supply Chain with Fast-Square software modules: in 2015 with CCO-Replenishment and in 2018 with CCO-Scheduler and CCO-ATP.

Fast-Square Software suit ranges from Demand Planning, Master Planning, Cut Optimization, Production Planning, Scheduling and soon also Transportation Management.

 

Dr. Monica Marcora, President Marcora S.p.A. said: “We are working with Gino Giannone and Fast-Square since more than 20 years and we continue to implement together new solutions tailor-made for our company.”

 

Benefits

 

Production Efficiency and Trim-Loss reduction has been the objectives and result of the first project. With the usage of CCO-Optimizer, Marcora has been able to quickly introduce Planners without experience to Production Planning activity, with no productivity decrease.

Benefits reached with the introduction of CCO-Scheduler are:

  • Global Visibility of Customer-Order availability

  • Better Control of Production Planning

  • Late Orders Reduction

 

Gino Giannone CEO Fast-Square said:

“This long-term collaboration is a demonstration of the quality of our software solutions and a recognition as trusted advisor. Marcora has helped us to cover the real requirements of a Steel Service Center, developing the tool in a real production environment.”