Manufacturing Efficiency Software: How AM Teams Can Reduce Cycle Times Without Buying New Machines

Introduction - More Machines Aren’t the Answer

Many additive manufacturing teams reach a point where throughput feels stuck. Parts take too long, capacity feels limited, and lead times stretch further than customers expect.

The first instinct? Buy more machines.

But in most cases, capacity problems don’t originate with the machines at all - they come from the workflow surrounding them.

Manufacturing efficiency software improves throughput not by scaling hardware, but by optimising:

• scheduling

• routing

• material flow

• human activity

• testing

• post-processing

• documentation

This article explains how manufacturing efficiency software unlocks hidden capacity and why it is often more impactful than investing in new equipment.

For broader workflow context, see: Additive MES Explained

Where Additive Manufacturing Really Loses Efficiency

Cycle time in AM isn’t just printing time. Far from it.

Actual cycle time includes:

• job preparation

• file transfer

• scheduling

• machine availability

• material handling

• manual checks

• post-processing

• waiting for external labs

• documentation and reporting

Without visibility, each of these becomes a bottleneck.

Let’s break down where inefficiencies typically hide.

1. Scheduling Bottlenecks

Most AM teams still schedule using:

• whiteboards

• spreadsheets

• shared calendars

These tools can’t handle:

• machine downtime

• priority changes

• material shortages

• operator availability

This leads to idle time - the silent throughput killer.

2. Material Delays

Material readiness issues cause:

• cancelled builds

• emergency re-planning

• partial batches

• incomplete runs

Often because teams didn’t know:

• which batch was available

• whether it was in spec

• whether re-use limits were exceeded

See also:➡️ [Internal Link: Future of Material Management]

3. Bottlenecks in Post-Processing

Post-processing often accounts for 60–80% of total cycle time. But many teams have little visibility into:

• backlog

• operator availability

• equipment readiness

• test lab delays

4. Machine Data Isn’t Used Proactively

Without integrated machine data:

• deviations go unnoticed

• reruns are discovered too late

• maintenance planning is reactive

• build failures cascade

These are avoidable with proper software.

5. Testing and Certification Are Disconnected

External labs create unpredictable delays when:

• results are emailed

• documents are unstructured

• data isn’t linked to workflow

This disconnect breaks efficiency and traceability.

Connected test workflows, as required in programmes like DECSAM, reduce these delays:➡️ [Internal Link: DECSAM Programme]

What Manufacturing Efficiency Software Actually Does

Efficiency software doesn’t make machines faster - it makes the workflow faster.

Here’s how:

1. Dynamic Scheduling & Routing

Software automatically:

• adjusts schedules

• reassigns jobs

• reroutes work

• predicts delays

• plans around downtime

This eliminates manual rework and idle time.

2. Real-Time Material Availability Checks

Before scheduling a build, the system verifies:

• batch availability

• re-use cycles

• certifications

• storage location

This prevents last-minute cancellations.

3. Workflow Automation

Approvals, routing steps, notifications, and documentation are handled automatically - reducing human-induced delays.

See: Smart, Traceable, Efficient

4. Machine Data Integration

Software ingests:

• thermal histories

• sensor deviations

• environmental data

• chamber logs

It then informs:

• downtime prediction

• build reruns

• quality reviews

• routing decisions

5. Integrated Post-Processing & Test Workflows

Efficiency software connects:

• machining

• heat treatment

• support removal

• blasting

• finishing

• CT scans

• tensile tests

Every step becomes part of the same digital thread.

Integrations with platforms like 3D Spark, Digifabster and Paperless Parts widen this ecosystem.

Efficiency Gains Without Buying a Single Machine

Teams consistently report measurable improvements when implementing modern efficiency tools.

Faster Turnaround Times

Jobs flow smoothly with fewer stoppages.

Higher Machine Utilisation

Fewer gaps in scheduling. Machines run more consistently.

Reduced Scrap & Reruns

Early detection of parameter deviations prevents waste.

Predictable Material Availability

Genealogy and readiness are always visible.

Streamlined Testing & Certification

No more chasing emails or missing data.

How to Deploy Manufacturing Efficiency Software Effectively

To get the most benefit:

Step 1 — Build the Digital Thread

This ensures all workflow data connects.

Step 2 — Centralise Scheduling

Give the entire team a real-time view of capacity.

Step 3 — Automate What Can Be Automated

Remove repeated manual steps.

Step 4 — Integrate Material, Machine & Test Data

The more context the software has, the smarter it becomes.

Step 5 — Standardise Workflows

Codify best practices across teams and sites.

Conclusion — Throughput Is a Data Problem, Not a Hardware Problem

Most additive manufacturing teams don’t need more printers. They need:

• fewer delays

• fewer errors

• fewer data gaps

• fewer manual steps

• fewer workflow inconsistencies

Manufacturing efficiency software delivers this by controlling the context around production - turning existing equipment into a more powerful, predictable, reliable system.

Efficiency isn’t about printing faster. It’s about wasting less.

Recommended Authentise Tools

• Authentise Flows - workflow optimisation & scheduling

• Materials Management - real-time material readiness

• Authentise Threads - testing & external lab integration

• Digital Design Warehouse - version control & design governance

Want to Increase AM Throughput Without Buying New Equipment?

See how manufacturers are using Authentise to reduce cycle time and unlock hidden capacity. Book a demo