Introduction
Since 1934, Simeg has been one of Italy’s leading companies in stone processing applied to design, particularly in the kitchen and interior furnishing sectors. The company combines artisanal culture with industrial organization, developing comprehensive expertise in transforming all types of materials: marble, natural stone, and ceramics.
The Problem
The main challenge faced by Simeg is the need to improve efficiency and reorganize the production of customized natural stone products, due to the growing number of clients and orders to manage.
The inefficiencies identified in the current process, characterized by very small production batches and multiple technologies (including manual data management steps), are:
- Heterogeneous data management: The technical office handles DXF files from different CAD systems (SolidEdge, AutoCAD) or custom trace files provided by clients. CNC programs are implemented in various ways (vertical CAM systems, machine-side programming, manual coordinate input from paper drawings). This fragmented system limits efficiency and process standardization.
- Fragmented and manual process: Production is organized on a job-order basis. The organization of production data is shared between the engineering technical office and various departments, resulting in programs being stored in different locations and formats. Manual data entry generates human errors and costly material waste.
- Technological and know-how limitations: CAD/CAM programming is mainly carried out at machine level instead of being centralized, limiting efficiency and the consolidation of company know-how.
The solution
The adopted methodological approach aims to create a centralized CAM Automation system positioned between the design and production phases, establishing a formalized “production technical office.”
The main project steps are:
- Analysis and standardization of inputs: Heterogeneous data formats from the engineering office (DXF files from SolidEdge and AutoCAD, proprietary files, and custom client traces) will be analyzed and standardized to make them interpretable by the CAM system.
- Design and development of input interfaces: Dedicated interfaces will be designed and developed for the CAM Automation system to manage different input types.
- Implementation and configuration of CAM Automation: The CAM Automation system will be installed and configured in a test environment (to avoid impacting actual production). The system will be customized according to Simeg’s production workflows.
The system will be customized according to Simeg’s production workflows. - Integration with CNC machines: Technical specifications of the CNC machines will be analyzed and dedicated post-processors will be developed to connect them to the central CAM system.
- Validation and Go Live: All interfaces and post-processors will be tested and validated. The CAM Automation system will then be configured in the final production environment and fully deployed.
This approach will automate the generation of CNC programs, reducing Time-to-Market and operating costs, consolidating company know-how, and minimizing manual errors and waste of costly materials.
Tecnologies
The main technological solutions used and developed for the project are:
- Centralized CAM Automation system: Introduction and configuration of the “Easystone” CAM Automation system, provided by partner DDX, which will become the core of the production process
- Ad hoc interfaces and post-processors: Dedicated interfaces will be developed and configured to standardize inputs from different CAD systems and client trace files
- Existing CAD systems: Integration of data from 3D CAD SolidEdge and 2D CAD AutoCAD systems, as well as proprietary software files and client-provided traces
Expected impacts
The long-term goal of the project is to support company growth and strengthen Simeg’s competitiveness by transforming the production process of customized natural stone products through CAM Automation implementation.
Expected impacts include:
- Efficiency and competitiveness: The introduction of a centralized “production technical office” will streamline functions and processes, relieving production departments from manual data management.
- Know-how consolidation: Storing NC programs in a single standardized repository will unify data management and consolidate company knowledge.
- Environmental and social sustainability: The project aims to reduce waste and material scraps (marble, quartz, ceramics) through process optimization, lowering raw material costs and waste disposal costs.
Benefits for the Company
- Reduced Time-to-Market: Shorter time required to start production of an item thanks to automated machining cycle setup.
- Reduced operating and raw material costs: Lower operating costs through more efficient data processing, and reduced raw material costs thanks to fewer scraps caused by manual programming errors.
- Greater efficiency and flexibility: Increased flexibility and efficiency, improving production scheduling through better data preparation.
- Enhanced competitiveness: Automation and production efficiency will support expected volume growth, making the company more competitive and able to respond more quickly to market demands.
- Human resource optimization: Operators will work with pre-set machining cycles, eliminating paper drawing reading and manual data input, improving comfort and reducing fatigue and stress.
In summary, the project enables the transition from a fragmented job-order organization to a standardized and centralized production flow.
The project developed in synergy with MADE represented a fundamental strategic opportunity for Simeg’s technological evolution. The adoption of a structured workflow not only made it possible to achieve the predefined outputs within the established timeframe, but above all enabled full integration of processes between the technical office and CNC production systems through CAM automation. This digital interconnection, applied to marble processing, optimizes the transition from design to physical production, ensuring superior precision and unprecedented operational efficiency.
Michele Quagliani
Operations Manager, SIMEG