Overview
Shearline type optimised cuts will invariably produce offcuts from the source stock.
Offcuts differ from scrap in that they are a length longer than the maximum scrap length permitted for the relative material and should be held for re-use at a later stage.
This article discussed methods available to examine the offcuts being produced and options available in the application for handling them.
Requirements
You will need access to the cut optimiser application and a working knowledge of how to use the system.
Identifying Offcuts in Cut Sheets
For shearline optimised cuts, the system will attempt to use any offcuts that have been previously entered in the system whether manually, by an operator on the production floor or updated from cut sheet calculations.
Typically offcuts held in system can be identified in the sources grid within cut optimiser with a priority below stock (typically 100% or higher). A lower priority forces the system to attempt to use the sources selected in that priority order.
Processing a cut will display how many stock and offcut bars will be used for the cut in addition to new offcuts that will be produced by the cut sheet (New ones will not highlighted in the Source Part Grid):
Note how none of the offcuts have been used in subsequent cuts of the cut sheet. This behaviour can be changed in the optimiser settings to re-use any offcuts generated during the cut if possible:
Options here are :
- Hold for re-use - Re-use the generated cut later in the cut sheet if possible
- Store - Drop all offcuts into the offcut holding bay
- Scrap - Break up any offcut generated and scrap
Re-running the same cut as above with "Hold for re-use" selected, the source parts list now appears as:
Assessing offcuts from Cut Sheet Print Outs
From version 2.1.50 of the Cut Optimiser program the cut sheet printout has been modified to improve readability of details of offcut and scrap.
Offcuts are more identifiable within the cut cycles:
The report summary has been adjusted to better allow for offcuts:
In the above example:
- 2,373 kg of source material has been used
- 2,276 kg of parts have been cut from the source (Yield Rate of 95.9%) (This figure does not include offcuts generated)
- 41 kg of Scrap has been generated (Scrap Rate of 1.7%)
- 20 kg of Offcuts have been generated (Offcut Rate not provided but is 100-(95.9 + 1.7)≈2.4%)
Altering Offcut On-Hand quantities
This is best done by having the correct device and site selected.
- Right click in the sources grid and select "Edit Offcuts"
- The following form will display:
- Existing rows may be edited by just overtyping the required value
- New rows may be entered by typing a qty or length (in millimetres) into the new row at the bottom of the grid values
- To delete rows,
- highlight the rows to delete by selecting the row header button.
- Right click the grid and select "Delete selected items"
- Once all values are correct press Save to commit the changes to Database.
Insufficient Stock Error messages during optimisation
The following error may appear during cut optimisations:
This indicates that there is insufficient stock to cut the amount of bar selected. Either:
- Reduce the amount of parts to be cut so that only the available stock that is available can be used.
- Adjust the on-hand values to account for stock received that has not yet been updated in the accounting package:
N.B. You must update the values just after selecting the product and before adding items to the parts to be cut. The source grid is updated and reset between cuts with the number of offcuts generated during the optimisation process.
After updating the on-hand stock values you must reselect the source items to be used in the cut processing. Use the right click menu in the source grid to select all available sources or select only the sources to be used by holding down the control key and selecting the required row headers:
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