Rebar processing automated!

PCM - Production Control Module

Complete process flow automated
Ideal machine utilization
Improved bar cutting optimization
Highly autonomous production
Immediate re-use of offcuts
Integrated master bundling
Exactly adaptable to your requirements by many parameters
  • Machine allocation

  • Prioritization

  • Production packages

  • Bar cutting optimization

  • Master bundling

  • Online Machine downloading

Process flow

  • Schedule

    • Entry/Import of schedules
    • Starting automatic machine allocation
    • Releasing schedules for production
  • Production unit

    • Creating production unit
    • Printing tags for non-PCM-controlled machines
    • Releasing production unit for production
  • PCM

    • Running constantly in the background
    • Reacts on changes e.g. change of delivery date, machine breakdown
  • In case of machine breakdown or maintenance, bar marks are automatically moved to next appropriate production line
  • Automatic machine allocation checks all priorities
  • Calculation of the production time for each production line
  • Appropriate bar marks are allocated to the offcut cutting machine
  • Integrated machine utilization and work load balancing
  • Parallel optimization processes (running simultaneously)
  • Various parameter sets (optimization parameters, box drawing, stock lengths, sorting)
  • Continuous optimization with various bar mark combinations
  • Configurable scoring system for rating the results
  • Sorting of the delivery units and bar marks according to configured parameters (Loading time, delivery date, scheduled production time)
  • Consideration of dependencies (Cutting and bending in two steps on different machines)
  • Backwards calculation to determine the latest production start and finish for each individual bar mark
  • Automatic combining of bar marks to bundles with defined weight, size and dimension
  • Takes into consideration the actual logistic possibilities and builds bundles based on diameter, machine, delivery unit or even across several machines
  • Handling of bar marks to be bent can be defined specifically (e.g. generally kept separately, but bundled together in case of sub bar marks and varying bar marks)
  • Combination of the bar marks to production packages
  • Configurable time frame and number of production packages (e.g. 12 x 2 hours)
  • Forward calculation to determine earliest production start and finish for each individual bar mark
  • Automatic, continuous downloading to the machines
  • Receipt of production feedback
  • Integrated heat management

Rebar processing partially automated! 

POM - Production Optimization Module

Supports the production planning process
Is used when creating production units (for one shift or the whole day)
Main goal #1: Optimal bundle creation (automatically)
Main goal #2: Balanced work load on all machines
  • Machine allocation

  • Automatic bundle creation

  • Work load balancing

  • Automatic optimization

  • Bundles & machine utilization

  • Manual interaction

  • In case of machine breakdown or maintenance, bar marks are automatically moved to next appropriate production line
  • Automatic machine allocation checks all priorities
  • Calculation of the production time for each production line
  • When the load balancing finished the bar cutting optimization is started automatically for all shearlines
  • The optimization process run parallel and the system uses all pre-defined parameter sets to find the best possible result
  • Identification of bar marks that have to be produced on one specific machine
  • Creation of bundles for bar marks identified in step 1 and adding other bar marks if possible
  • Creation of bundles for remaining bar marks
  • Additionally, bar marks can automatically be re-allocated to another production line to further reduce the total number of bundles
  • The re-allocation is based on the previously performed possibility checks and taking into consideration the time to produce on the corresponding production line
  • The maximum bundle weight depends on the setting in the subsidiary, machine and on customers restrictions
  • The bundle size can be further limited by the number of bars and diameter of the full bundle
  • The results of the automatic master bundling is displayed in an interactive overview
  • Beside the overview, the balanced out work load is shown in a machine utilization diagram
  • Furthermore, the scrap and offcut summary of the selected best result from the bar cutting optimization appears per shearline
  • After creation of the first bundle suggestion, the work load on the machine is balanced out automatically
  • The system takes into consideration the shift working times and the individual machine productivity
  • Appropriate bundles can be re-allocated the another production line when all bar marks of the bundle can be produced there
  • The user can influence the rules of work load balancing with separate priorities
  • Bundles can be re-allocate to other production lines by the user
  • After a manual re-allocation the bundle optimization process as well as the bar cutting optimization is restarted for the specific machine


In our industry also more and more customers are dealing with this issue. There is a fundamental interest in technical progress, because it is always a chance to realize an increase in efficiency in all sections. For this industry the so-called „Digitization“ is no exception.

On the following pages we would like to introduce two new modules. Firstly it is the module PCM (Production Control Module), on the other hand there is the module POM (Production Optimization Module).

It is our concern to make the know-how of LENNERTS & PARTNER that was put in these modules also accessible to you. Our support includes the conception regarding integration of the program systems to your company as well as the best care after installation by our support team.


Back in 2017 we have already started a project with a customer in Australia to further automate the production processes in a rebar shop.

Therefore, the involved machine manufacturer developed a new concept of logistic handling to automize the bundling and tagging of the single bar marks and to enable an integrated master bundling over several machines. Based on this concept and in close cooperation the LENNERTS & PARTNER GmbH created a module which provides the necessary data for bundling and tagging on the one hand and consistently automizes the further production steps on the other.

The module PCM is permanently running in the background, supplements the manual production planning and replaces the manual downloading via barcode scan.

Machine allocation – For allocation all defined priorities will be checked and the production time for each production line will be calculated. When there is a machine breakdown or a maintenance, the bar mark items will automatically be reallocated to the next suitable production line. Also offcuts will be managed and suitable bar marks will be allocated to the respective offcut machine. An integrated machine utilization and the load distribution complete the assignment.

Prioritization – Delivery units released for production will be sorted by configurable parameters (loading date, delivery date, scheduled production date) and brought into the right order. Here also dependencies (cut and bend in two steps on different machines) will be considered. The process will be completed by a reverse calculation to find the latest production start and end for each single bar mark items.

Production units – Next the bar mark items to be produced will be combined to production units. With these production units a high flexibility can be reached and machine breakdown will be prevented. Here the size and number of production units is freely definable (e. g. 12 x 2 hours). Unlike with the prioritization here a forward calculation is made for determination of the earliest possible production start and end for each single bar mark.

Bar cutting optimization – In the module PCM the bar cutting optimization is made automatically. Here for each shearline different parameter sets (optimization parameters, bin system, stock lengths, sorting) will be used as well as different bar mark combinations will be passed. The single optimization processes can be started in parallel. To valuate the results a configurable scoring system will be used.

Master bundling – Bundles will be combined automatically from the single bar mark itmes with defined weight, cross-section and dimension. Here the logistic possibilities are considered and master bundling is made on the basis of steel diameter, machine, delivery unit and also over all machines. Features like handling of bar mark items to be bent can be specifically defined (e. g. in general single transfer, but combine parted and graduated bar mark items).

Machine downloading – In the module PCM the downloading of machine is made autonomously and continuously. So data will not be requested by barcode scan, but will be transferred automatically upon receipt of production feedback of the previous bar mark items. Of course, also in this case the cast number management integrated in the downloading is available.


Automatic master bundling – After start of the module first an automatic re-allocation of bar mark items which are allocated to inactive machines (breakdown or maintenance). Then bar mark items will be identified to be produced on a special machine. These bar mark items will be supplemented to big bundles by adding further bar mark items. Here the maximum number of bars, the maximum bundle weight and the cross section of the bundle will be considered. In the next step the remaining bar mark items will be combined in bundles.

To reduce the total number of bundles, bar mark items can be reallocated to other production lines on the basis of a possibility check made before. The maximum bundle weight depends on the settings in the subsidiary, the machine and other customer restrictions. For a homogeneous master bundling the bar mark items will be classified according to categories based on the geometry of the shape code.

Balanced work load – Based on the shift times and the individual performance of each machine an automatic balanced work load will be made. Here suitable bundles will be relocated to machines checked before. The rules for this balanced work load can be defined with separate priorities.

Bar cutting optimization – If the balanced work load is completed, the bar cutting automization will be started automatically for all shearlines. The optimization processes run parallel and use all predefined parameter sets in order to achieve the optimum result.

Bundle and machine allocation – The result of the automatic bundling will then be shown in an overview. In addition to the overview, the balanced work load will be presented in a work load diagram. Also for each shearline a summary of the bar cutting optimization will be shown and it is possible to look at the cutting lists.

Manual allocation – The user has the option to reallocate complete bundles or single bar mark items later. Here the master bundling process and possibly the bar cutting optimization for affected machines will be repeated.

Information about PCM and POM