Zedis, a Catalan family-owned company specializing in customized merchandising and point-of-sale solutions, faced precisely this challenge: transforming an efficient yet fragmented production process into a connected, flexible, and future-proof manufacturing system. Previously, the machines at Zedis operated side by side. With its customized smart factory, the Spanish family-owned company has made the transition to data-driven production.
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“We used to just react; today, we set the pace,” says José Velasco. He is the purchasing manager at Zedis, a Spanish sheet metal fabricator with clients such as Maserati, L’Oréal, and Orange, which has comprehensively modernized its manufacturing operations. The result: a custom-built smart factory. Data-driven production brings transparency to processes and enables real-time interventions. Today, errors are detected before they occur, downtime is kept to a minimum, and bottlenecks are identified early on.
The data continuously provides new insights—we learn something new every day.
Customized solutions for retail
The Catalan family-owned company Zedis, located near Barcelona, develops and manufactures customized merchandising and point-of-sale solutions for globally recognized brands, as well as street furniture and outdoor
Previously: Fragmented processes
The project that was set to transform Zedis fundamentally was launched in early 2024. The starting point was similar to that of many SMEs: the metalworking operations were technically sound but structurally fragmented. Although the machines operated with precision, they worked in isolation. Data remained in silos, processes broke down at interfaces, and there was virtually no integration.
Cutting, bending, storage – everything worked in isolation, but not as a unified whole. “We had production islands, but no control over the workflow,” recalls Velasco. The aim was an integrated solution that would make the entire process – from order receipt to the finished part – transparent and controllable, including order, material and machine utilisation.
“We realised that our future lies in connectivity,” says Procurement Manager José Velasco. “When we decided to modernise, it was clear:
We don’t just want to replace machines; we want to rethink our entire system.
Technological expertise from Switzerland
This is where Bystronic came into the picture. “We had already become familiar with a Bystronic smart factory in Northern Europe,” says Velasco. The Swiss technology proved convincing: machines, automation and software work together seamlessly.
Zedis opted for a comprehensive system that intelligently links material and data flows. Bystronic acted as a total solution provider, supplying the machines, software and expertise for this digital ecosystem. “We particularly appreciate that Bystronic tailors solutions to our needs and acts as a long-term partner. Our mindsets are a perfect fit: Bystronic supports us in the same way that we support our customers,” says Velasco.
Full control over the business
Today, the four towers of the ByStore warehouse form the heart of production. Connected to them and fully automated are two bending cells – an Xpert Pro Bending Cell and a ByBend Star – as well as a ByCut Star 3015 laser cutting system. All production units are linked via BySoft Shop Floor and can be controlled centrally. The software acts as the digital nervous system of the manufacturing process, enabling work planning to be adjusted at any time.
BySoft Shop Floor connects the new machines to the company’s existing ERP system. The manufacturing process is now traceable from start to finish. Real-time data from machines and the ERP system now runs synchronously: stock levels update automatically, orders are allocated precisely and bottlenecks become immediately visible – enabling seamless planning without manual data reconciliation. This digitalisation was crucial for Zedis. “Now we have full control over our business,” says Velasco.
Changeovers without any downtime
Flexibility has also reached a new standard. Individual customer orders can be processed almost seamlessly. In the past, this meant changeovers and downtime. Today, a few clicks are all it takes to start a new order with completely different parameters.
“Two orders involving different materials can be processed one after the other,” explains Velasco. “The software, the tools, even the dies switch over automatically.” The result: shorter lead times, consistent quality, less waste. This sets Zedis apart from similar facilities in Southern Europe and it is already regarded as a centre of excellence – even though the expansion is not yet complete.
A partnership that strengthens both parties
For Bystronic, the project is an example of how technology and entrepreneurial spirit complement each other perfectly. “We have established a partnership with Zedis in which both sides learn from one another to help shape the future of the sheet metal industry,” says Joan Vicaria, Sales Manager at Bystronic. Zedis benefits from the technology, and Bystronic gains valuable insights from practical experience for further developments.
Doubling on the horizon
Whilst Zedis continues to refine the system during ongoing operations, the next phase of expansion is already in the planning stages. Phase two envisages doubling the size of the smart factory facility. The plans are in place, the infrastructure is ready.
Today, Zedis is where many aspire to be: at the interface between industrial tradition and the digital future – with a smart factory that creates full transparency, increases productivity and enables optimisations during ongoing operations.
