Tim Smith
Subject Matter Expert – Manufacturing & Owner of TSRB Systems LLC
In today’s high-speed, precision-driven manufacturing world, laser cutting tables equipped with sophisticated cassette towers have become the backbone of advanced fabrication operations. These systems deftly process large sheets of metal, rapidly producing hundreds of parts per run with remarkable accuracy. Nesting software such as SigmaNEST optimizes every layout to squeeze the most value out of each sheet, while advanced fiber lasers from companies like Mazak Optonics slice through materials with surgical precision and speed.
Yet despite their technological brilliance, these setups have historically struggled with one stubborn blind spot: accurately determining true per-part processing costs. Traditional costing approaches fall short when multiple operations—piercing, etching, drilling—are distributed across nested sheets containing hundreds of parts. The result? Plant managers are left making costly guesses, quoting with unpredictable margins, and missing crucial opportunities to optimize profitability.
The Challenge: Cracking the Code on Per-Part Costs
Imagine a high-capacity laser table drawing sheets from a cassette tower, working on a 10-foot by 5-foot stainless steel panel. Each job might contain hundreds of components—brackets, flanges, custom shapes—nested by SigmaNEST to maximize material yield. As the laser navigates the sheet, it pierces here, etches there, drills holes elsewhere—an orchestrated ballet of operations across dozens or even hundreds of parts.
SigmaNEST's nesting engine can reduce scrap by 4% or more compared to traditional layouts, while Mazak Optonics’ fiber lasers, such as the Optiplex 3015 NEO, use adaptive beam shaping for exceptional speed and cut quality.
The problem? These operations aren’t executed one part at a time. One piercing might apply to 20 parts, a single etching pass could affect dozens, and hole drilling might jump across part clusters. When the job finishes, there’s a stack of neatly cut parts—but no clear record of how much time or cost each one truly consumed.
Relying on methods like dividing total job time by part count is overly simplistic and misleading. Even ERP systems, while great for material and labor tracking, often lack the granular operational data needed for real per-part costing. This gap leaves managers flying blind, risking underbidding, losing margin, or leaving improvement opportunities untapped.
The Breakthrough: Real-Time Data and Integrated Intelligence
Enter 2025, where advanced operational management solutions like Efficient Manufacturing from TSRB Systems transform this dynamic. By integrating real-time data capture with flexible tools like SigmaNEST and advanced Mazak Optonics laser technologies, manufacturers can finally achieve per-part cost clarity.
Unlike traditional monitoring that focuses on uptime or simple OEE (Overall Equipment Effectiveness), Efficient Manufacturing delivers deep, actionable insights by capturing and analyzing granular, operation-level data. According to TSRB Systems’ implementation results, manufacturers adopting this approach have experienced productivity gains of 10% to 50%, often with ROI achieved in under four months.
Here’s how it works: SigmaNEST optimizes part layouts, reducing material waste and cutting times. However, beyond just nesting, SigmaNEST’s post-editing capabilities allow engineers to embed instructions in NC programs that direct the laser to send specific signals to Efficient Manufacturing during each operation—piercing, etching, or drilling.
Mazak Optonics’ machines, such as the Optiplex 3015 NEO and FT-150 NEO, equipped with SmoothTUBE Control and TUBE DX software, can execute these advanced instructions seamlessly. When integrated with Efficient Manufacturing, each laser operation generates precise time-stamped signals indicating what operation occurred, which parts were affected, and how long it took.
Imagine a nested sheet containing 200 parts. During processing, the laser performs 50 piercings, 30 etchings, and 100 drill operations, each affecting various part groups. Efficient Manufacturing captures each of these signals, aggregates the data, and automatically assigns the correct time and operational cost to every single part.
By the end of the run, managers receive a detailed breakdown: Part A took 12.3 seconds to process, Part B took 15.7 seconds, and so on. Combining this precise time data with other known costs—energy, labor, consumables—enables true, validated per-part costing. The result? Confident quoting, maximized margins, and powerful insights for process optimization.
Why It Matters: From Guesswork to Precision
The integration of Efficient Manufacturing, SigmaNEST, and Mazak Optonics represents more than just a technological upgrade—it’s a fundamental shift in operational strategy. Here’s how it unlocks 10% to 35% efficiency gains and safeguards profitability:
Precision Quoting and Profit Protection
Without accurate per-part data, manufacturers often inflate quotes to hedge against hidden costs, risking lost contracts to more agile competitors. With real-time data, every quote is backed by precise cost validation, allowing managers to compete aggressively without sacrificing margin. As one example, Smucker Laser, leveraging similar integrations, reported the ability to process significantly more quotes per day, increasing win rates and customer trust.
Proactive Process Optimization
Dashboards powered by Efficient Manufacturing deliver live performance insights directly to operators and managers. Repeated bottlenecks—such as excessive piercing—can be addressed on the fly. SigmaNEST can then be adjusted to reduce piercings, while Mazak’s beam-shaping technology fine-tunes cut speed and quality.
TSRB Systems’ data shows that real-time visibility has enabled plants to cut downtime, improve throughput, and achieve typical efficiency improvements of 10% to 35%.
Advancing Sustainability and Meeting ESG Goals
Sustainability isn’t optional—it’s a market expectation. Efficient Manufacturing can track energy use per part, integrate with Mazak’s CNC systems to monitor kilowatt-hour consumption, and combine with SigmaNEST’s material optimization to minimize scrap.
This level of detailed reporting supports compliance with emerging SEC climate-disclosure rules and positions manufacturers as partners of choice for environmentally conscious customers.
Competitive Edge in a Demanding Market
While many manufacturers still rely on static ERP data or manual tracking spreadsheets, those equipped with real-time intelligence and smart tools run lights-out shifts, optimize quotes, and attract higher-value contracts. The operational gap between early adopters and laggards continues to widen.
Getting Started: Three Practical Steps
1️⃣ Connect Your Laser for Real-Time Data
Begin by installing Efficient Manufacturing on a key laser cutting table. Integrate it with the machine’s CNC system to capture operation-level signals. Starting with your highest-volume or most complex machine provides rapid insights and early ROI.
2️⃣ Enhance Your Nesting Program
Partner with your SigmaNEST provider to modify NC programs for detailed operational reporting. This step requires minimal adjustment and can be piloted on a single job to validate accuracy before scaling plant-wide.
3️⃣ Empower Your Team
Leverage Efficient Manufacturing dashboards to share insights openly. Encourage operators and supervisors to identify and resolve bottlenecks in real time, fostering a culture of continuous improvement and shared ownership.
The Bottom Line: Unlocking the True Potential of Laser Cutting
In 2025, the laser cutting sector stands at a critical crossroads. With rising market demands, margin pressures, and sustainability mandates, manufacturers can no longer afford blind spots in their costing or operations. The integrated power of Efficient Manufacturing from TSRB Systems, SigmaNEST, and Mazak Optonics laser systems provides a clear path forward.
By combining real-time, per-part data capture with intelligent process optimization, plants gain true cost clarity, unlock 10% to 35% efficiency improvements, and future-proof their operations against market volatility.
Your laser table and cassette tower already hold tremendous potential. By adopting this smarter, data-driven approach, you can turn complex, high-mix jobs into opportunities for growth, precision, and profitability.
Start small—connect one machine, test one job—and let the data illuminate hidden opportunities. In a year where every second, every part, and every kilowatt-hour counts, embracing these tools is not just an option—it’s a competitive imperative.
Don’t just cut metal—cut through complexity and build a stronger, more profitable future.