Connecting CAD design to the factory floor

Years ago, Planstudio identified one of the manufacturing sector’s most significant pain points: the gap between CAD design data in the technical office and execution on the production line. Historically, companies used one software for technical design and a completely different one on the shop floor. This disconnect resulted in communication errors, misaligned data, and incorrectly manufactured parts.

“We all know that these errors cost a lot of money,” Massimo explains. “The very first thing clients would tell us in meetings was: We want to avoid errors, because they cause huge delays and problems when the goods arrive at the construction site.“

Planstudio’s solution was to build a seamless digital bridge. Using Bentley’s MicroStation as the core engine to import, manage, and analyze complex 2D and 3D CAD models, Planstudio integrated these capabilities with their in-house developed software, Progenio MAXX.

While MicroStation ensures data precision and handles the heavy lifting of the CAD models, Progenio MAXX takes that exact data and sends it directly to the cutting and processing machines on the factory floor, effectively eliminating the margin for human error.

How Paolini scaled furniture manufacturing with MicroStation

The ultimate test for this integrated solution came through their partnership with Paolini. The initial challenge was daunting: managing the sheer volume of data for a production line that processes an astonishing 200,000 components every single day.

Planstudio went far beyond a standard software installation. They worked side by side with Paolini’s team, often staying until midnight on the shop floor, observing the machines, and ensuring the workflow was flawless. “We worked together as if we were one single company,” Massimo recalls.

The project resulted in a historic milestone: Paolini became the first company in its sector to implement an RFID (Radio Frequency Identification) system. By using these smart, scannable tags, Paolini can automatically track the exact real-time location of every single furniture component as it moves through the production area.

The business results were spectacular. In the first year of implementing Progenio MAXX alongside MicroStation, Paolini recorded a 70% growth, maintaining an impressive 30% to 50% year-over-year growth in subsequent years. The transformation was so impactful that Paolini became an industry benchmark, prompting other companies across Italy to seek out Planstudio to replicate this success.

Looking ahead, Planstudio sees a sea of opportunities. Massimo estimates that many companies in the sector still operate with traditional, manual methods and desperately need digital transformation. With plans to expand into new European markets like Germany and Poland, Planstudio aims to leverage Bentley’s global partner network to facilitate their international growth.

What Bentley partners can learn from Planstudio

When asked what advice he would give to other Bentley partners aspiring to drive similar digital transformations, Massimo’s response was rooted in deep customer understanding:

Planstudio proves that with the right technology foundation and a deep understanding of industry pain points, there are no limits to growth. And it all starts with a solid partnership—or, as they put it, “love at first sight.”