Automation has evolved from a useful option into a strategic necessity for staying competitive. A shortage of skilled operators, shrinking batch sizes and shorter lead times are prompting companies to organise production more intelligently. Tom Verhaeghe, International Product Manager for Lasers at LVD Group, explains how laser automation is helping meet these challenges.
Why automation?
“Laser cutting technology has evolved spectacularly over the past decade. Fiber lasers cut faster than ever before. The question is: how do you ensure the rest of the production process keeps pace? In many cases, the biggest productivity gains no longer come from cutting faster, but from eliminating downtime between jobs.
Tom Verhaeghe, LVD Product Manager Laser
“Automation used to be mainly associated with mass production. Today, manufacturers are handling ever-smaller production runs involving a growing variety of materials and sheet thicknesses. More changeovers and manual handling increase idle times and reduce return on investment.
“Many companies still believe automation limits their flexibility. They worry, for example, that urgent jobs can no longer fit into the schedule. But that’s not true. Automation systems – both hardware and software – can switch quickly between materials and jobs while dynamically adjusting priorities.
“And the benefits go far beyond speed. Operators spend less time loading and unloading sheets and more time monitoring production, ensuring quality and preparing the next processing steps.”
“Automation systems – both hardware and software – can switch quickly between materials and jobs while dynamically adjusting priorities.”
LVD laser automation all in one
Discover the complete line-up in one dynamic video.
Compact Tower
From a simple system to a fully automated flow
At LVD, automation doesn’t have to start with a large warehouse system. Companies can begin with an entry-level laser such as the LaserTWO, combined with a Load-Assist loading system.
“Our philosophy is simple: customers should be able to grow with their automation. That’s why every LVD laser cutting machine is automation-ready and our automation systems are modular,” Tom explains.
“The greatest efficiency gains come when machines, automation and software work perfectly together.”
A configuration can evolve from a basic setup with a single Compact Tower to a Tower Automation System (TAS) and ultimately a fully integrated Warehouse Automation System (WAS) supplying multiple production machines.
The objective remains the same: minimise plate-to-plate time. That means faster loading, automatic switching between materials and sheet thicknesses, and intelligent unloading of finished parts.
A cut sheet can be automatically returned to the warehouse, sent directly to an unloading table for an urgent order, or transferred to the next production cell. This keeps the production flow moving.
Software: the hidden power
According to Tom, anyone who thinks automation is mainly about towers and warehouses is overlooking its most important component: software.
“At LVD, laser cutting machines and automation systems share the same database for cutting technologies, material data and process parameters. Operators no longer need to adjust settings or search for the right programs.”
Within the CADMAN-JOB software module, it is determined which machine will execute a job, what material is required and the cutting technology to be applied. Based on this, a job list is generated and made available on Touch-L, the laser cutting machine control.
When the machine needs material, Touch-L automatically sends a request to Touch-A, the automation control. Touch-A then ensures the correct sheet is supplied without operator intervention.
“The operator no longer needs to make manual adjustments. The software ensures the right material reaches the right machine at exactly the right moment.”
Choosing the right solution
“A system that doesn’t fit the production process is, in fact, already too expensive,” says Tom.
“That’s why we start every automation project with a thorough analysis of the customer’s needs and production process.”
What materials are processed? What are the typical batch sizes? How long are the cutting cycles? Is buffer capacity required? How much floor space is available? The answers determine which solution offers the best return on investment.
Financially, the options also vary considerably. A simple loading and unloading system represents only a fraction of the cost of a laser cutting machine. At the other end of the spectrum, you have fully integrated Warehouse Automation Systems (WAS), where multiple towers automatically supply various lasers, punching machines and other production cells. These systems are actually part of the infrastructure and last for several generations of machines.
Why LVD laser automation?
Modular automation that grows with your production
Seamless integration of machines, automation and software
Smart software for the right material at the right time
Tailored solutions for the best return on investment
Transforming production flow
A customer example clearly illustrates the impact automation can have.
“A customer wanted to replace his four laser cutting machines – two fiber lasers and two CO2 lasers – with just two machines. You might think this would reduce capacity, but thanks to automation, productivity increased significantly. The newest of the existing machines, a Phoenix, was integrated into a WAS automation system alongside a new Puma fiber laser with higher laser power.”
“The WAS (Warehouse Automation System) is positioned at the centre of the production line. Raw sheets that enter at one end, are automatically stored to be later supplied to either of the two laser cutting machines. The cut parts exit at the other end, moving directly to the next production step - press brake bending, assembly or welding. This automated flow reduces material handling and handling errors while keeping the lasers running more efficiently.”
Investing during quieter periods
Economic uncertainty often causes manufacturers to postpone investments. According to Tom, quieter periods can provide the perfect opportunity to prepare for the future.
“Exactly then, companies have time to critically evaluate their production,” Tom says. “Many use that period to map out an automation strategy. When demand picks up again, they’re ready to scale up much more quickly.”
Photo: Warehouse Automation System
THE FUTURE
Smarter factories and autonomous production
“For years, the focus was on ever-higher laser power. Today, that evolution seems to be reaching both technical and economic limits. The biggest innovations are shifting towards software, connectivity and automation.
“Artificial Intelligence will play an increasingly important role in optimising production planning, nesting, sorting, and many other processes. At the same time, machines are continuously collecting data on their own performance. They enable predictive maintenance, helping to avoid machine downtime. The factory of tomorrow will operate more intelligently than ever.”
SO...
Staying competitive starts with automation
Whether it’s a compact entry-level solution or a fully automated warehouse system, the greatest efficiency gains come when machines, automation and software work perfectly together.
“Automation today is about much more than increasing your capacity,”
Tom concludes. “It’s a strategic investment that makes companies more flexible, better organised and future-ready. Ultimately, it allows you to get more out of your machines and out of your scarce technical staff.”
