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Nesting Latest News, Product Novelties, Fairs and much more
DECEMBER 2013
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index
LANTEK LINK is a Magazine of LANTEK SHEET METAL SOLUTIONS
COVER Photo: Broadbeach Bridge
03
EDITORIAL
06
SOLUTIONS
10
TECHNOLOGIES
12
NEWS
14
SERVICES
Harder, Better, Faster
Queensland, Australia
LANTEK MARKETING TEAM Jesús Martínez Marketing Director
Beatriz Prado Production, Publishing, Design
When nesting, does it pay to be the early bird?
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MAIN TOPIC
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INTERVIEWS
11
INNOVATION
13
CASE STUDIES
15
EXHIBITIONS
Lantek stands out with its nesting solutions
Rob Powell, Lantek UK Sales Director
Patricia Ruiz de Sabando Communications and Public Relations
SUBSCRIPTIONS Marketing
Welding preparation
marketing@lanteksms.com
Lantek agrees the incorporation of their cutting solutions in the machines of Pierce Control Automation
Lantek Services Lantek Hint: Lantek Flex3d
What if we manufacture 400 km above the Earth?
Lantek Expert a reliable, fast and easy solution for Intec Laser Services
Next Tradeshows
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editorial
A
Harder, Better, Faster
s we start the New Year, we are looking forward to releasing the 2014 version of our products. R&D is putting the finishing touches to what will be the Spring 2014 Global Release. We are looking forward to unveiling its contents and we hope to do so very soon. 2013 was a really tough year for us in which our capabilities and versatility were put to the test. We have achieved a new breakthrough in terms of understanding the needs of our customers, evolving with them and building working models together to ensure improved performance of our solutions. As each project gets underway, we are learning about the challenges we face and incorporating them in subsequent projects. After several years of implementing increasingly ambitious projects, we have consolidated our knowledge and built key capabilities so our clients can achieve the best return on their investments. The 2013 version has brought a significant improvement to the market in terms of the performance of CAD/CAM 2D and 3D systems and our business management platform. We have found the way that the cooperation of these systems with one another and with external systems through our interconnection mechanisms is really outstanding, achieving reductions in losses and really sensitive workflow improvements. As we begin 2014, we are clearly stronger, better and faster.
JesĂşs MartĂnez
Lantek stands out with its nesting solutions In addition to the advantages of its products for the general market, Lantek solutions offer added benefits like auto nesting, nesting of remnants via kits, with significant time and material savings. It is well known that nesting is a software system based on algorithms that take maximum advantage of and optimize the parts that you wish to cut or punch. It is a work system that aims to produce all the parts needed for a given project, optimizing the use of one or more sheets of sheet metal and other materials used in the metal industry. In other words, with this system, the operator can visualize the pieces and position them for cutting or punching in a way that maximizes each plate to include all possible pieces and cut them in the shortest
time possible. Nesting improves quality, reduces costs and shortens production time. Common problems in metal processing companies include material waste, which results from not having technology that allows them to maximize every sheet of metal and a lack of agility in the nesting process itself, since it must be done manually or with slower solutions. These two disadvantages slow down the response of the company to its customers and make the process increasingly expensive.
along with a substantial reduction in material losses and production times. Lantek’s nesting solutions offer advantages such as nesting for remnants, which allow a company to save and store leftover remnants from previous jobs for subsequent reuse. Furthermore, Lantek provides a logical interface that is adaptable to production requirements, allowing parameter verification with just one single window. Lantek technology is also recognized for nesting of interior contours and nesting solutions for common cuts, superior in quality to those on the market, as it synchronizes the width of the manufacturer’s machine torch with Lantek software in order to cut pieces of the same or different lengths in less time.
Given this need, there are many companies that have decided to invest in specific software in addition to implementing improvements in machinery and proprietary technology. The goal? Growing in the market by providing a comprehensive response that combines the quality of their products, the best price, and meeting their customers’ deadlines and requirements. Among the Lantek software solutions, we highlight the Lantek Expert family, which specializes in nesting processes for parts and programming for machine cutting, compatible with various technologies such as Oxy fuel, Plasma, Punch, Shear or Water Jet. Its main competitive advantage is the return that a company can obtain from the material used, thanks to the system designed by Lantek based on artificial intelligence that incorporates powerful algorithms and mathematical morphology strategies that allow greater usability of the plates,
Among other needs presented to companies in the sector is the need to optimize their design processes, cutting and assembly of the components that make up a single end product. The nesting of these pieces is typically done separately; however, with Lantek’s technology, a company can manage its order comprehensively through nesting via kits. In other words, performing the nesting for cutting, just one-time, provides all the parts needed for a product without having to wait for parts in stages. The difference in this kit solution is that the user can choose the kit configuration, not just the product configuration, based on its needs. Lantek also facilitates switching between automatic and manual nesting, depending on the specific needs of production, being able to switch between the two options at will. In addition, other differences of Lantek technology are the ability to automate processes, a cut above the rest, and the technical possibilities to anticipate solutions to hypothetical problems foreseen by methodological rules. All these advantages place Lantek software among the most advanced, fastest, and most effective on the market. Proof of this is that today, more than 13,000 customers around the world use Lantek technology.
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solutions
Adria Illes Lantek USA Sales Director
When nesting, does it pay to be the early bird? Not always - especially in the job shop Country music legend Willie Nelson is credited with saying, “The early bird gets the worm, but the second mouse gets the cheese." It’s unlikely that Willie was reflecting on manufacturing. Regardless, his quote still summarizes perfectly one of the greatest challenges sheet metal fabricators face: When nesting, is it better to be early, or just in time? We have all been taught that to be early is to be on time. In fact, being on time is likely the most crucial component of any manufacturing business. Stakes are high, and manufacturing companies win loyal customers with their ability to deliver quickly and reliably ahead of their competition. Being lean is likely the next most critical aspect. Lean businesses reduce waste and thereby cost to win orders with competitive prices. A key lean philosophy is just-in-time (JIT), whereby businesses reduce cost by avoiding the waste associated with overproduction, waiting, and excess inventory all while meeting delivery deadlines. Nesting finds itself at the crux of these two critical business practices.
When to Nest? Nesting early does not necessarily mean that parts will be cut early, creating physical part inventory to manage. You can store CNC programs of nests for later use. Once you nest parts, you know the optimized material requirements. Being the early bird (nesting early), you know precise raw material requirements in advance. With these optimized requirements, you can buy material needed in time for the work to be done, and be selective in shopping for a supplier. Your operation can consume these raw materials right away and eliminate the costs associated with warehousing raw material inventory. Money is then not tied up in stock materials, extensive warehouse space, or inventory management. In this manner, your operation can have the right material at the right time. In other words, you can be lean. Nesting too early, though, or being the first mouse, can be lethal. The geometry of any part in a nest might change, as could the due date. Say you nest several jobs together, all with a due date three weeks away. Then you get a call from the salesperson; one customer needs his part sooner than expected. So you send that entire nest to the laser or punch. That customer’s part is cut on time, but all those other jobs aren’t needed for several weeks, so they are placed into inventory. The same thing can happen if the due date is postponed. Then, as your cut parts sit in inventory, one customer calls with a design change. Design changes to a part already cut leads to out-ofprocess rework. If rework isn’t possible, those parts become scrap. So in essence, parts nested too soon can
cause substantial waste as nests must be recalled, parts scrapped or reworked, nests reprogrammed, and CNC files remade. Nesting too early can also waste material. You might decide to nest parts early on a certain day, because the shop workload seems to be a bit light, and the material yield may be acceptable. By getting a head start on this job, you keep the people and machines on the floor busy. So you cut the job early, and the parts sit in WIP as they wait several days to be formed in the press brake department. The next day a small order comes in that requires the same material, but with a tight deadline. You have no choice but to buy another batch of the same material. Moreover, the material yield may be very poor. Had you not nested those parts the previous day, you could have nested both jobs on the same sheet, increasing your yield. You also would have made just one raw material purchase, saving time in your purchasing, accounting, and administration departments. You also may have gotten a discount for purchasing material in bulk. This would have saved not only freight costs, but also your receivers’ time. Waiting to nest all the parts together certainly would have reduced programming time and the time required to load and unload machines. Of course, nesting too late also can be a problem. You may nest at the last minute to avoid problems from lastminute changes, but this also might delay a material
purchase, creating a shortage. Waiting for materials to arrive is wasteful and certainly not lean.
tools that present real-time information, visualization is nearly impossible.
That’s why businesses that nest late usually buffer against a shortage with minimum stock, purchased based on historic estimates or gross part weight. But this requires a certain level of demand certainty for specific parts and material types. If you don’t manage your stock carefully and ensure your operation consumes the buffer stock steadily, that buffer can become an expensive disaster.
An enterprise-level system that shows orders as they are received, and includes part geometry for those orders, allows programmers to consider all required production, without leaving their desks in search of new sales orders and associated part geometry. Having visibility of more demand allows programmers to incorporate more parts and achieve better yield, requiring fewer raw material purchases.
Demand Stability Many manufacturing businesses aspire to be early birds to ensure on-time delivery. But early-bird nesting isn’t for everyone. To nest early and still be lean requires demand stability, where parts ordered are known and the flow of orders for parts is consistent. Demand stability is possible for an original equipment manufacturer (OEM) or an uppertier supplier whose primary business is making consistent products with only minor variation. The demand stability allows the manufacturer to determine the right number of days to hold demand to nest efficiently, buy the right material, and have it delivered on the right day. For job shops, though, demand stability is not possible. In fact, demand can fluctuate dramatically, even with blanket orders. Existing orders can change regularly as well. Nesting too early in this environment is the same as being the first mouse and getting caught in the trap. It leads to many small material purchases (sometimes several in the same day for the same material), expediting fees, and, ultimately, a full scrap bin or large variety of small-quantity raw materials stagnating in stock. If you nest early in this environment, you probably will alter that nest to accommodate changes. This can cost a tremendous amount of manual labor and rework. To be lean and on time, your job shop has to be the second mouse. You need to nest at just the right moment to combine orders and optimize a range of raw materials. And you must place raw material orders at the last safe moment to receive material in time to meet deadlines. Supply Stability and Demand Visibility As the second mouse, you also need supply stability, or the ability to receive required raw materials on time readily, consistently, and cost-effectively. For this, you need a great relationship with a reliable vendor. Instead of always shopping around for a closeout from an unknown and potentially unreliable vendor, try reducing the number of vendors you work with and trusting their costs. This saves time and helps build good business relationships. To know when to nest, you must know if you’re a bird or a mouse, and plan accordingly. With demand stability, nesting early can have great benefits. With supply stability, nesting later becomes practical and offers a tremendous savings. To build a good supplier relationship, you also need demand visibility, or the ability to see exactly what’s occurring on the factory floor, in real time. No doubt, demand visibility can be challenging. In fact, without effective software
Good to Be the Mouse A job shop’s highly variable demand makes demand visibility all the more important. Demand visibility allows your business to plan accurately. If you can visualize both demand and WIP, you can accurately predict the next available delivery date. Job shops don’t have the luxury of demand stability. But with demand visibility and supply stability, your job shop can be the second mouse. You can nest late and still get the cheese.
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interviews
Rob Powell Lantek UK Sales Director
“The functions that save companies time and money, are superior in Lantek Expert�
He joined Lantek in September 2000, which was 6 months after the company started in the UK. His first role was Regional Sales Manager for the southwest of the UK. It is never easy starting up in a new market but, using the large number of contacts he had in the industry, he soon started to get interest and generated his first sales. In 2005 he was asked to take over as Manager for the UK which is a role I continue to carry out, balancing the management of the company while continuing to work on direct and distribution sales, which he finds both challenging and enjoyable.
To start with, could you explain us how Lantek Expert and Lantek Flex3d have evolved in the world of CAD/CAM software during these years? Lantek Expert has come a long way since 2000 when we were distributing version 10. It has always been the highest selling product in the UK and it is encouraging that it is continually developed year on year. I think the current version sees the best nesting algorithm improvement since I started with the company. Lantek nesting has always been among the most advanced in the market and, I think, the industry has always accepted that Lantek offers one of the best systems for profiling. Over the years, the punching functionality has caught up and is probably one of the most advanced packages on offer today. The markets for the tube cutting and steelworks products have always been fairly small in the UK but, the Lantek Flex3d Addins is very popular and always demonstrates very well. As regards CAD interfacing, many of our competitors, some of which have Gold status partnerships, have too many restrictions when working with CAD at Assembly Level. Our customers seem to be very satisfied with the depth of functionality we offer for all of the mainstream 3D CAD systems. What are the biggest differences between Lantek and other software companies in the world? Could you tell us why the customers buy Lantek over other software? My experience is that Lantek do the major things very well compared to other CAM systems but we also haven’t lost sight of some of the simpler things. The continued development of the CAD for instance has very often put us in a good position. During demonstrations some of the CAD functionality leaves more of an impression on potential customers. I have seen more people impressed by the auto dimensioning and the preview of the part displaying time and cost than the nesting and remnant management, which Lantek does far better than most of its competitors. Nesting is crucial of course, but many systems do that well.
My view is the functions that save companies time and money such as automatic bridging and common line cutting, which are superior in Lantek Expert, especially when you are able to show the time savings per sheet, quickly demonstrate where we are better than competitive products. Additionally, I believe that the wide range of products that Lantek offers is appealing to many customers. Knowing that they can expand the system in the future is always a positive point when making a decision. What is the relation between Lantek and Lantek distributors? How the distributors of Lantek work with the final customers? We have a number of partners in the UK. On the machine tool side it is mainly used machine tool distributors and we work with a number of these now. The product is a major part of why they work with us. However, I also I think they chose Lantek as a partner because of the service we offer. Additionally, we have a good working relationship with several Solid Works distributers, who recommend us to their customers. What role do the manufacturers play for Lantek business? We have a good relationship with plasma machine manufacturers including KERF developments which is currently are our bestselling new machinery partner. The key benefit we get from these partnerships is software sales into areas which are difficult for us to access such as Scotland and Ireland. Conversely, our software also shows their machines to their best advantage so both parties gain from the relationship. Lantek Factory comprises the most complete portfolio in the industry to cover all the needs in a metal factory. What is your opinion about this new concept and the Lantek offer? How do you explain this to a potential customer so they understand the benefits of it? The new concept of Lantek Factory brings together the range of our products most suitable for the needs of each individual company. Getting customers to look at the overall performance of their whole business rather than an isolated area can bring much greater benefits. Our task is to help managers to understand that by combining products to cover more of their business, the associated improvements will be much greater.
What kind of request is most popular in UK? New developments, new version, services like maintenance, one of our products. New developments are always popular, and this is probably why so many of our customers renew their maintenance contracts every year. The high level of renewal of maintenance contracts still remains one of the major success stories for Lantek UK. I don’t see this changing as the rate and number of contract renewals keeps going up year by year. In your opinion, which are the most important advantages of Lantek CAD/CAM compared with other software in the market? The range of products we offer, how they can be combined, and the functionality of those products is unique in the market. Although Lantek Expert continues to be the best product for us, the advantages for customers that integrate our other modules into their businesses will give them a clear competitive edge. Which would you say it is our competitive advantage about our automatic nesting system compared with the rest of the offer available in this market? The major advantage of Lantek nesting from a customer point of view is the ability to work with multiple sheets, thicknesses, and machine tools. Once you load the required parts into a job the system sorts it and will apply all the pre-defined machining strategies for you. The ability to apply the consumable saving options automatically is also a major advantage. On the punching side the feedback we get is that our automatic tolling is far more configurable than many of our competitors’ software, eliminating the need to apply a manual tool path. And finally, what is the strategy for increasing the presence and the market share of Lantek in the British market? Our intention is to increase sales into markets like Scotland and Ireland including Northern Ireland over the coming year. We also need to keep working with partners which increases our sales representation in these areas. Additionally, we are continually striving to make companies more aware of the full product range we offer both in demonstrations and by big improvements in our web presence.
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technologies
Oscar Hualde Software Engineer
Welding preparation
The preparation of the connections between pieces is a fundamental part of the welding process. The quality of the solder is entirely dependent on the attention paid to preparation and, in many cases, faulty connections between pieces can be attributed to incorrect preparation. The most important preparation work should be focused on cleaning surfaces and chamfering edges.
Chamfering For pieces of less than 4 mm thick, it is not necessary to chamfer the edges that require joining. When welding is carried out, the edges of the welded parts are placed at a distance equal to half their thickness. The weld requires that there is penetration. If the pieces to be welded are very thick, the full thickness cannot be penetrated, which is why the edges must be chamfered to allow the welding to be performed and for total penetration. Different chamfering strategies exist: V-shaped chamfers involve making a 30째 recess, for example, on each edge of the pieces that have to be welded.
Once joined, a 60째 gap is left. For very thick pieces, X-shaped chamfers can be made, consisting of two partial chamfers, one on each side of the joints. The choice of chamfering type for weld preparation is a compromise between obtaining adequate access and reduced volumes of solder. This choice depends on the process used for joining and material thickness. A small angle requires less solder material, so the process can be more economical when greater thicknesses are used. On the other hand, the disadvantage is that the smaller the angle, the harder the access and the greater the risk of defects such as lack of sidewall fusion. This reduced access can be compensated by carrying out partial chamfering in order to obtain a larger contact area between the surfaces to be joined. The task of chamfering can be performed manually with a hand-held radial saw or with a machine specially designed for this function. Those machines that have a 5-axis head require CAD/CAM software to facilitate chamfering. During machining, this software allows the edges of the pieces being joined to be chamfered for the welding and obtain total or partial V-shaped chamfers.
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innovation
RaĂşl Alvarado Software Engineer
What if we manufacture 400 km above the Earth? What do astronauts do when they need a spare part they do not have on board? Their only option is to order the part from Earth and wait for the next Soyuz spacecraft supplies. This could change soon because of 3D metal printing. Although stereolithography has been around for decades, the most popular 3D printing technology today is Fused Deposition Modelling (FDM). It consists of heating a strand of material to melting point and placing it in a certain position. When the thread is cooled, it solidifies. Typically, the material used is a thermoplastic, such as ABS. Following similar methods, alternatives have been tested ranging from jet printing with liquid metal (with useful creative potential for electronic circuits) to food printing in several layers (pizza). FDM plastic parts are usually only suitable for rapid prototyping. On the other hand, there is a
more precise technology which is being used increasingly in short runs of final pieces. This is the case with the hinges of Airbus 320 (pictured in the foreground), certain fire arms and fuel injectors for General Electric LEAP engines. With Direct Metal Laser Sintering (DMLS), the process begins with designing the pieces in a CAD system. Then the planes are interpreted by software that decomposes the model into horizontal layers of fractions of a millimeter and controls a printer. The printer has a tray on which a fine mantle of metal powder is deposited. A laser is applied that melts specific metal granules, thus achieving the first layer of the model. The tray then descends, again depositing metal powder for the next layer and repeating the process until the product is completed. Finally, excess powder is removed and collected for further fabrication. Compared with classic manufacturing techniques, DMLS has some limitations. Not all finishes can be achieved and, for now, the process is subject to the random threat of accidental air bubbles. However, the designs may have a complex geometry. The parts have no joins and are stronger and lighter than traditional parts. Alloys can also be used (even with expensive metals such as niobium and platinum) without wasting material. There are signs that next year will be the definitive explosion of DMLS. The European Space Agency launched the AMAZE project, the goal of which is to take a metal printer to the International Space Station. As patents related to this technology expire in 2014, a significant reduction in the cost of overpriced printers is also expected. The aerospace and automotive industries will not be the only industries to benefit. The consequences may affect areas such as medicine, jewelery, toys and robotics. So what do astronauts do when they need a replacement part for their 3D printers?
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news Lantek agrees the incorporation of their cutting solutions in the machines of Pierce Control Automation
Lantek Expert will be integrated in the plasma cutting machines of the Czech manufacturer The agreement is part of the strategy of alliances that Lantek has with the leading manufacturers in the machine tool market
The international market continues to place its trust in Lantek technology, a leading company in the development and marketing of software solutions for the industry. Proof of this is the new global agreement recently reached with the manufacturer of plasma cutting machines, Pierce Control Automation. Under this agreement, Pierce Control Automation will incorporate the Lantek Expert CAD/CAM system for plasma cutting to optimise the operation of their machines. In this way, the company reaffirms its commitment to deliver the highest levels of quality and performance in their products, fulfilling the specific needs of each customer. Since it first started operating, Pierce Control Automation – a company with Australian origins but with its headquarters in Europe, in the Czech Republic – has been dedicated to the development and production of cutting machines that incorporate the most advanced and innovative technology on the market. The company is operating globally and currently exports its machines to all the continents, selling in more than 30 countries.
The agreement with Pierce Control Automation is part of the strategy of alliances that Lantek deploys with the leading manufacturers of machine tools in the market, to provide innovative, powerful and flexible solutions for the metal industry. Also, through these agreements, the great adaptability of Lantek solutions to meet the requirements of each manufacturer, and the capability to tackle any type of project in any environment and on any machine is clearly demonstrated. Lantek has opted for the creation of a network of partners which is made up of companies and manufacturers with a high level of competence and prestige within the industry. Pierce Control Automation will become part of this network to the benefit of both companies, not only in commercial and market terms but also from the technical point of view, ensuring, above all, exceptional quality in the implementation of solutions and ultimate customer satisfaction. Also, this partnership marks the beginning of a professional relationship between the two companies that will help them consolidate their position in the metal industry at international level.
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case studies Lantek Expert a reliable, fast and easy solution for Intec Laser Services Intec Laser Services was the first UK customer for Lantek and its Lantek Expert CADCAM software. Since it was formed in 1979, Intec Laser has grown steadily and was the first Laser Cutting company to be part of the DSM Group. This group now encompasses six Laser Cutting sites around the UK with locations in Bristol, London, Wakefield, Rugby, Cannock and Redditch. Most of the sites operate using Lantek’s software.
The company specialises in the subcontract market and has customers in a very wide range of industries including aerospace, defence, automotive and white goods, supplying parts cut by both laser and waterjet. The six sites all have similar top end equipment from Trumpf, Bystronic, Flow and Amada, programmed by multiple licences of Lantek Expert. Typical of its equipment is Intec’s 6kW Trumpf L3030 fully automatic laser cutting machine fitted with a TrueStore sheet handling unit which is located at its Redditch site. This enables the company to produce suitable components unmanned overnight. Here Lantek’s facility for microjointing helps to keep parts securely in the sheet. Dave Millar, Managing Director says, “We tend to use rectangular nests as we are generally making 10 or 20 sheets of the same product.
Dave Millar Managing Director “The software has a robust translator. Other software we have tried will not reliably open the great variety of filetypes supplied by customers from their various CAD systems. With Lantek, you feed the design in and you are immediately ready to generate the CNC programme. Overall the software is very easy to use - we do all our training in house now. Lantek Expert is a robust trouble free tool we depend on every day as part of our busy business, making it a key element and essential part of our successful operation.”
Without microjointing parts could jam the machine which may result in the loss of a full night’s production.” The speed of programming possible with Lantek Expert is one of the major benefits of the software combined with its easeof-use. Dave Millar adds, “Because we are in the subcontract industry we have a continual flow of new parts. Lantek Expert programming is extremely fast helping us keep up with customer’s demand for very short lead-times. In addition, when we have a bottleneck in manufacture, Lantek allows us to very easily switch nests from one machine to another amazingly quickly with just two mouse clicks, greatly improving the flexibility of production.” Intec Laser likes the DXF and DWG interface in Lantek Expert.
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services Check the QR code for more information! UPGRADE
Lantek Hint Configuring scribe lines in Lantek Flex3d Addins Did you know that scribe lines generated in Lantek Flex3d Addins, which are marked so they can be folded, can be configured so the entire line does not have to be marked, but only one part on each side? In this way no time is lost by marking the entire line.
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exhibitions • Every year, Lantek is committed to being present at the sector’s most important fairs, both at a national and international level. • Request your invitation by scanning the QR code.
TOLEXPO 2013 PARIS- FRANCE
FABTECH 2013 CHICAGO - USA
19 - 22 NOVEMBER
18 -21 NOVEMBER
Next Tradeshows
SIMTOS 2014
BIENAL MÁQUINA HERRAMIENTA 2014
EUROBLECH 2014
APRIL 09-13
JUNE 02-07
OCTOBER 21-25
SEOUL- KOREA
BILBAO - SPAIN
HANNOVER - GERMANY
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Do you know Lantek Factory? info@lanteksms.com
Lantek Factory is a concept developed by Lantek that comprises all the plants that process sheet metal, tubes, and beams. With Lantek solutions, the customer fully manages their activities to achieve greater levels of competitiveness and productivity. These companies manage their work implementing the Lantek systems and integration mechanisms in order to have absolute real-time control of everything that is going on in the business.
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