Above: Cincinnati Inc.’s software is designed to help operators move a part from digital to physical accurately and efficiently
March, 2025- Manufacturing software has transformed from generic, basic, standalone systems into custom user-friendly platforms that make tasks more accurate, provide real-time feedback, feature custom tools and nesting profiles, and offer tailored experiences.
One factor driving technology forward is the skilled worker shortage.
“As experienced workers retire and fewer individuals enter skilled trades, manufacturers are turning to software and automation to bridge that gap, streamline operations and maintain productivity,” says Edwin
Diaz, Cincinnati Inc. software product manager. “Software simplifies complex tasks, reduces training time and empowers less experienced employees to perform at higher levels. Modern software often includes built-in tutorials, simulations or step-by-step guides to train employees more efficiently.”
Making software simpler and more intuitive not only makes it easier for newer employees but also allows fabricators to focus their skilled workforce on more critical operations.
“The goal nowadays is to take someone that’s new to bending or cutting and have them operating the software competently within three, four months of training or even less,” Diaz says, often with the help of an experienced operator. “Modern interfaces are more user friendly, featuring drag-and-drop functionality, customizable dashboards and extreme visuals, almost like a video game.”
IT’S AUTOMATIC
Cincinnati has been operating in the machine tool industry for 125 years, shipping more than 60,000 machines with rugged, premium features that stand up to demanding environments. And the company’s expertise has grown to include software that best maximizes the machine, reducing idle time and scrapped parts or material.
“Early software was text-based and generic, and now, we offer custom tools and custom nesting profiles that are more company-specific,” says Diaz. “The solutions also integrate seamlessly with the ERP and MRP systems, creating more of a unified workflow. You can take a CSV file from an ERP and drag all those parts into the software without having to do it one by one.”
Cincinnati’s BendSim PRO software allows manufacturers to simulate production, reducing the time needed to physically test parts at the machine and throwing out scrap in the process. “Now, you’re not physically wasting material or time,” says Diaz.
BendSim PRO automatically adds tools and sequence, creates the simulation and outputs the code for the press brake, Diaz says, and it can add multiple parts at once in a batch. “In theory, if an experienced operator has already set up the preferences, a new person could come in and run the programs automatically. Depending on the difficulty of parts and the kind of tooling, the success rate would be from 60 to 80 percent.”
BendSim PRO can enable batch processing of multiple parts, as well as automated tooling selection and tool station placement.
Similarly, on the laser side, Cincinnati offers Nesting PRO, which makes it easier to cut parts with advanced features, batch them and handle different material thicknesses. Again, “once you set up the parameters on the machine, another operator can come in and hit auto,” Diaz says.
CIberDash collects live data from controls and gathers it into an easy-to-read dashboard.
“The goal is to take away the calculations you would normally do in your head and put it into the software.”
The ability to link software through the cloud also has expanded its possibilities. “It isn’t limited to the local machine. You can remote in. For example, if some tools are added and the operator is on vacation or sick, I can pick up my computer and see all those new tools because we’re all synced on a shared network.”
That connection also enables industrial software to leverage data, allowing manufacturers to respond quickly to market changes and production challenges. Once the soft-ware is installed, Diaz says customers realize they can use it to discover new business, without sacrificing current work, including testing out new tools before purchase.
COMPUTING POWER
Advanced, flexible algorithms and AI not only can replace repetitive tasks but also reduce waste and enable predictive maintenance and autonomous software decision-making. “The more you use it, the more it understands,” Diaz points out.
“It eliminates manual programming, and that can reduce time from one hour on the computer to five minutes, which is a lot more time to be cutting metal,” he continues. “The simulation software on the BendSim PRO, will evaluate whether a part can be bent or formed, or if it will crash the machine. These digital simulations reduce the need for physical prototypes, saving time and materials. The nesting software also minimizes scrap and maximizes material use because the capabilities of the computer are much faster and more advanced than the human brain when it comes to running a large number of permutations.” And the material saved can be put into inventory for future use.
Cincinnati also offers a cloud-based machine monitoring software called CIberDash, which collects data from the controls and gathers it into an easy-to-read dashboard with built-in notifications to indicate if a machine has gone offline or if it has encountered an error. “CIberDash enables quick identifications of different issues that persist on the machine, predicting when maintenance is needed to reduce unplanned downtime and extend equipment life span,” Diaz says. “If the machine isn’t going up and down or cutting material, it’s not making money.”
UP AND RUNNING
Cincinnati realizes that many shops feature equipment from a variety of manufacturers, and the software is equipped to handle that through an OPC-UA utility, eliminating the inefficiency of running several different types of software. It works will all standard design files and easily handles changes to design and production schedules, re-simulating parts without disruption to the flow.
Nesting PRO allows users to create enhanced nests, complete batch conversion of flats or 3D models, and program automatically.
It also provides ongoing support, including software updates, training resources and troubleshooting assistance to keep operations running smoothly. Diaz says, though, that any software requires a little upfront effort and time from customers if they want to take advantage of its full capabilities.
“I always tell people to give it two weeks putting preferences and tools in. It will save you hours down the line. If customers don’t set it up, they’re still relying on manual processes. A lot of customers have a misconception that it should run right out of the box. Well, every company has different tools and different preferences. We could make it run right out of the box, but it would be pretty generic. For it to operate like a well-oiled machine, you have to spend time putting your values in. But if you do that, you’ll definitely see results.”
Cincinnati Inc., e-ci.com
