True impact Ai Case Study

Decorative Panels Ltd

Ai-Driven Packaging Optimisation & Cutting Automation

Overview

Client Type: UK flat-pack furniture manufacturer

Team Size: 60 employees

Challenge: High admin workload creating and maintaining cutting files for over 500 packaging part codes

Goal: Reduce manual effort, eliminate errors, cut material waste, and streamline production preparation

Measurable Impact

> £3,000 + saved in manual file creation of the initial cutting files (admin reduction)

> £3,000+ saved every time specifications change (admin reduction)

> £8,000+ per year reduction in planned material waste (8% waste saving)

> 10+ hours per week saved on cutting time

> Significant reduction in operator errors due to clear, consistent file naming

> Repeatable process for future changes

“True Impact Ai saved us an incredible amount of time and money.

What used to take us a full month now takes minutes — and the optimisation cut our material waste by 8% straight away.”

Dale Meakin, Decorative Panels Ltd

CLICK BELOW TO WATCH it in action!

The Problem in plain english...

Decorative Panels had recently invested in bringing cutting-table capability in-house.

But generating the cutting files — and naming them correctly so operators knew which material to use — became a massive bottleneck.

They had:

  • 500+ part codes.

  • 7 different material types.

  • A process that required manually creating, checking, and naming every single file.

  • No way of knowing what was the optimal sheet size to minimise waste.

  • Frequent specification changes, meaning the whole process had to be repeated regularly.

The team would’ve spent at least a full month manually creating and naming every cutting file, and even then they would have defaulted to a standard board size — accepting unnecessary waste as part of the process. They weren’t aware Ai could solve this problem, but that’s where Ashley Moscrop, CEO and Founder of True impact Ai, stepped in and showed them how a practical Ai solution could eliminate the bottleneck and optimise the entire workflow.

Our Ai solution

We built a practical Ai-driven system tailored exactly to how their production team works — not a generic tool, but a solution built around their real workflow.

1. Intelligent Part Code Analysis & Grouping

Ai analysed all 500+ part codes, identified patterns, corrected inconsistent naming, and automatically grouped everything by material type. This eliminated duplication, errors, and the hours normally spent sorting and checking data.

2. Automated Sheet-Size Optimisation (with Scenario Testing)

We created a custom optimisation engine that not only calculates the most efficient sheet size for each material type, but also runs multiple scenarios to find even better ways to maximise material utilisation.

It evaluates options for:

  • Minimum waste.

  • Minimum cutting time.

  • Maximum efficiency for future batches.

  • Alternative sheet sizes that could further reduce cost and waste.

This gave Decorative Panels insights they simply wouldn’t have had time to discover manually.

3. Auto-Generated Cutting Files

We engineered an Ai workflow that:

  • Creates every cutting file automatically.

  • Uses a consistent, intelligent naming format.

  • Embeds both the part code and material type in the filename.

This dramatically reduced operator error and made it far easier for staff to pick the correct material without confusion.

4. A Repeatable Web App for Unlimited Future Use

To ensure the solution continues delivering value, we built a secure web application with user login access, allowing Decorative Panels to:

  • Upload as many part codes as they like.

  • Re-run the optimisation anytime.

  • Generate new cutting files in minutes.

  • Repeat the entire process whenever specifications change.

  • Maintain consistent waste savings long-term.

What used to take them a full month now takes minutes, and they can repeat it as often as they need — without relying on external support.

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COMPANY DETAILS

128 City Road

London

EC1V 2NX

United Kingdom

Company Number: 16906475

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