Planner insights for the tablet industry

Abstract

The present invention is entitled Planner Insights for the Flat Panel Industry. Planner Insights analysis identifies customer executable orders and sizes to achieve business and operational efficiencies. Generating an optimal trimming pattern for trimming raw rolls and / or sheets of flat panel stock / customer orders includes: (a) receiving customer orders, primary machine specifications and secondary machine specifications, warehouse inventory, and trade constraints; and (b) generating solutions for: (i) order quantity fulfillment, (ii) primary cutting pattern for primary machine, (iii) secondary cutting pattern for secondary machine, and (iv) inventory details, wherein the solution is generated taking into account initial trade constraints; (c) performing batching and generating recommendations; (d) using revised trade constraints derived from recommendations generated in (c) that replace the initial trade constraints to generate modified solutions for the parameters in step (b); and (e) operating the cutting equipment. A pruning optimization knapsack algorithm with an objective function is employed, the objective function having terms related to the ultimate minimized pruning loss.

Description

Technical Field

[0001] The present invention relates to techniques for improving pruning operations in the flatbed industry, and in particular to an overall pruning planning process that integrates a quality control system with primary and secondary pruning equipment and generates pruning solutions that are based on yield or loss rather than on minimization of main rolls to meet customer needs. Background Art

[0002] The flat panel industry produces steel, paper, aluminum, dry plastic film, lithium ion separators, digital displays, etc. in the form of raw rolls or sheets. The raw rolls or sheets have varying widths, diameters (or lengths), quantities, and qualities. The width and diameter of these raw rolls depend on the specifications of the machines that make them. Customers often order product rolls or sheets that are smaller than the size of the raw rolls or sheets. Therefore, the raw rolls or sheets must be cut or trimmed into product rolls or sheets.

[0003] In the paper industry, paper machines produce large rolls of paper, called spools. The width of the spool is called the deckle and is usually fixed for each machine. Trimming or drafting uses secondary processing equipment, including, for example, winders, rewinders, sheeters, trimmers, and cutters. The winder cuts the spool into rolls with smaller diameters and widths. Trimming (also called secondary processing) is performed in one or more steps or stages, depending on the specific size of the drafting required. Typically, multiple steps are required due to the inherent limitations of the secondary processing equipment in its ability to handle different sizes.

[0004] Trimming is typically performed multiple times a day or week, and these drafting operations may include separate drafting for each shift or as a group of customer orders (called a drafting batch). The trimming process primarily involves determining the necessary trimming pattern according to which large raw rolls and / or sheets are processed on secondary processing equipment to fulfill a group of customer orders. The attributes of a customer order are typically width, diameter (or length), order quantity (within certain tolerances), product type, and delivery date.

[0005] Pruning is a classic combinatorial optimization problem where the solution is to find the right combination of various customer orders on winders of the same product type to achieve some goal. Most pruning algorithms focus on minimizing the number of master rolls used to meet customer demand while relaxing the upper bound on demand constraints, rather than minimizing pruning losses. As a result, suboptimal solutions are derived for the original problem. The algorithm may also result in almost no usable solutions. Techniques are needed for obtaining pruning solutions based on minimization of yield or losses rather than rolls. Summary of the invention

[0006] The present invention is based in part on the development of analytics that identify the sizes and quantities of rolls and / or sheets of material that are particularly suitable for trimming in a particular batch by associating the cost impact of size. The analytics provide a variety of recommendations regarding orders and sizes that the customer can make in order to achieve business efficiencies. These planner insights or strategies will reduce subjective reliance in planning by reducing the costs associated with manually performing multiple iterations to achieve the desired trim loss, and will improve operational efficiency, such as by minimizing winder usage and enhancing secondary equipment throughput.

[0007] In one aspect, the present invention relates to a method of generating an optimal trimming pattern for trimming raw rolls and / or sheets to fulfill flat stock and / or customer orders, the method comprising:

[0008] (a) Receive customer order specifications;

[0009] (b) receiving preliminary machine specifications;

[0010] (c) receiving secondary machine specifications;

[0011] (d) receiving warehouse inventory specifications;

[0012] (e) receiving transaction constraints;

[0013] (f) generating solutions for the following parameters: (i) order quantity fulfillment, (ii) primary cutting pattern of the primary machine, (iii) secondary cutting pattern of the secondary machine, and (iv) inventory details, wherein the solutions are generated taking into account the received transaction constraints;

[0014] (g) execute batches and generate recommendations;

[0015] (h) generating a modified solution for the parameters in step (f) using the revised trading constraints resulting from the proposal to replace the initial trading constraints generated in (g); and

[0016] (i) Operate the cutting equipment by:

[0017] receiving reels or sheets of material to be cut;

[0018] configuring the cutting device using the modified solution generated in step (h); and

[0019] The cutting device is configured to operate to cut the reel or sheet of material into a plurality of smaller reels or sheets.

[0020] On the other hand, the present invention relates to a trimming system, which comprises: a computer device, which automatically calculates the above-mentioned optimal trimming pattern; and a cutting device, which is used to cut a roll or a material sheet into multiple smaller rolls or material sheets, wherein the cutting device is configured to receive a modified solution generated by the computer device.

[0021] The present invention is characterized by the use of pruning optimization, which includes column generation, which internally uses a knapsack algorithm with an objective function that contains terms related to the ultimately minimized pruning loss. Specifically, the purpose of the knapsack algorithm is to include the duality of both the upper and lower demand constraints and the reduction of the total pruning loss. The objective function of the knapsack algorithm is not to minimize the total number of rolls used in a batch. The knapsack algorithm also integrates the demand upper limit and the minimum fixed edge. Typically, the knapsack algorithm creates a pattern with only a single fixed edge for a given set of sizes. If the set size cannot be cut from the given fixed edge, another (or secondary) knapsack algorithm is used to generate the mother roll. The unique method of the present invention allows a single knapsack algorithm to be merged for both the mother roll width or the order width. Specifically, the knapsack algorithm processes the mother roll for secondary processing using a single knapsack program, which has constraints related to size restrictions in secondary processing and the number of cuts in primary processing and secondary processing. The innovative knapsack formulation takes into account the edge losses and other constraints of both primary cutting and secondary cutting. The present invention provides a suggestion for reducing pruning losses, which is applicable to the shadow price concept.

[0022] A batch is a group of must-fulfill orders and optional orders of the same or similar product type that are grouped together and produced by drawing large original rolls and / or stock rolls and / or sheets. Trimming losses are quantity losses during the drawing process of cutting large original rolls and / or sheets into smaller product rolls and / or sheets as specified in a customer order. A customer order or order is a customer or internal stock order that typically includes product specifications, product name, product dimensions such as size (width), length or diameter, quantity in rolls, weight measurement unit, customer name, delivery schedule, product price and specific discounts (if any).

[0023] While the invention will be shown as being implemented in papermaking, it will be appreciated that the invention is generally applicable to any complex converting facility and other continuous sheet manufacturing processes, such as, for example, in manufacturers of rubber sheets, plastic films, metal foils, and the like. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1A is a schematic diagram of a papermaking system;

[0025] Figure 1BA system for implementing the planner insights model of the present invention is shown;

[0026] Figure 2A and Figure 2B are respectively a plan view and a perspective view depicting the operation of the winding machine;

[0027] Figure 3 The general strategies of planner insights for the flatbed industry are shown;

[0028] Figure 4 is a flow chart of the overall trim planning process with an integrated quality control system and primary and secondary equipment;

[0029] Figure 5 is a flow chart of the pruning planning process with the recommendation system; and

[0030] Figure 6 is a flowchart of the algorithm. DETAILED DESCRIPTION

[0031] like Figure 1A As shown, sheet material manufacturing system 10 includes a paper machine 2, a quality control system 4, and a network 6. Paper machine 2 produces a continuous sheet of paper material 12 collected in a take-up reel 14. Paper material 12 is made from a pulp suspension stock consisting of an aqueous mixture of wood fibers and other materials that undergoes various unit operations monitored and controlled by quality control system 4. Network 6 facilitates communication between components of system 10.

[0032] The paper machine 2 includes a headbox 8 that evenly distributes an aqueous pulp suspension onto a continuous screen or wire 30 on the machine that moves in the machine direction (MD). The headbox 8 includes a slicing opening through which the pulp suspension is distributed onto a screen or wire 30, such as a mesh for receiving the pulp suspension and allowing water or other materials to drain or leave the pulp suspension. The formation of the sheet 12 is affected by a plurality of linear actuators 3 extending transversely across the formed paper sheet 12. The actuators 3 control the weight of the sheet in the cross direction (CD). Sensors located downstream of the actuators measure the properties of the sheet. The stock is fed from the headbox through a gap or elongated orifice 5 onto the wire section 30. Weight distribution control in this arrangement is achieved by locally adjusting the position of the slicing lip across the machine with a motorized linear actuator 3 to change the size of the gap or orifice immediately adjacent to the actuator.

[0033] The sheet 12 then enters a press section 32 comprising a plurality of press rollers, wherein the sheet 12 travels through an opening (referred to as a "nip") between a pair of counter-rotating rollers in the press section 32. In this manner, the rollers in the press section 32 compress the pulp material to form the sheet 12. As the sheet 12 travels over a series of heated rollers in the dryer section 34, more water in the sheet 12 is evaporated. The calender 36 processes and conditions the sheet 12, for example by smoothing and imparting a finish, thickness, gloss, or other characteristics to the sheet 12. An array of induction heating actuators 24 applies heat to one or more of the rollers along the CD to control the roller diameter and, thus, the size of the nip. Once processed by the calender 36, the sheet 12 is collected onto a reel 14.

[0034] The sheet manufacturing system 10 also includes an array of steam actuators 20 that control the amount of hot steam projected along the CD. The hot steam increases the paper surface temperature and allows water to be removed more easily from the paper sheet in the cross direction. In addition, to reduce or prevent over-drying of the paper sheet, the paper material 14 is sprayed with water in the CD. Similarly, an array of rewet shower actuators 22 controls the amount of water applied along the CD.

[0035] In order to control the papermaking process, selected properties of the sheet 12 are continuously measured, and the papermaking machine 2 is adjusted to ensure sheet quality. Typical physical properties of paper that can be measured include, for example, thickness, basis weight, moisture content, chemical composition, surface roughness, gloss, thickness, and wrinkle pattern surface features. CD control can be achieved by measuring sheet properties using one or more scanners 26, 28 that can scan the sheet 12 and measure one or more properties of the sheet 12. For example, the scanner 28 can carry a sensor for measuring the dry weight, moisture content, ash content, or any other or additional properties of the sheet 12. The scanner 28 includes a suitable structure for measuring or detecting one or more properties of the sheet 12, such as a collection or array of sensors.

[0036] The measurements from the scanners 26 and 28 are provided to the control system 4, which regulates various operations of the paper machine 2 that affect the longitudinal properties of the sheet 12. The longitudinal properties of the sheet 12 generally refer to the average properties of the sheet 12 that vary in the longitudinal direction and are controlled. In this example, the quality control system (QCS) 4 is capable of controlling the dry weight of the paper sheet by regulating the supply of pulp to the headbox 8. For example, the QCS 4 may provide information to a pulp flow controller that regulates the flow of pulp through a valve and to the headbox 8. The QCS 4 includes any hardware, software, firmware, or combination thereof for controlling the operation of the sheet making machine 2 or other machine. The QCS 4 may, for example, include a processor and a memory that stores instructions and data used, generated, and collected by the processor.

[0037] The manufactured parent or master rolls are processed through secondary equipment to produce sub-rolls, which are stored in warehouses. Reels from different paper machines usually have different edges and grades, and each reel can be made into several sets of rolls. The width and diameter of these rolls must meet the customer's requirements specified in the customer order. Sometimes the manufacturer may produce more or less products than the ordered number (within the specified tolerance range). Production exceeding the order quantity is called overproduction, and production below is called underproduction. Trimming is the process of cutting the reel to prepare rolls. The pattern for trimming is a combination of different roll widths that add up to a given edge size.

[0038] Some paper machines and paper mills have giant processing machines, which include paper machine reels, coaters, extruders, and rewinders. The giant machine performs the first cut on the parent roll or master roll. In this case, the giant processing equipment includes the primary equipment, and the winder is part of the secondary equipment. For the planner's perspective of the present invention, the primary equipment refers to the device that performs the first cut, and the secondary equipment refers to the device that performs the subsequent trimming.

[0039] like Figure 1B As shown, the optimization model of the present invention can be implemented in a planner insight system 40 including a processor 42, a memory 44, an input device 46, and an output device 48. The memory includes a database for storing information input by the input device or otherwise. The planner insight system 40 is operably connected to the primary equipment and secondary equipment described herein.

[0040] In various flatbed industries, a set of specific equipment (e.g., winders, rewinders, sheeters, trimmers, cutters, etc.) is used for drawing or trimming. When there is no giant processing machine in the factory, the winder is called the primary processing equipment. The winder is a web cutting device that converts a large giant paper machine reel into a smaller roll. It winds the reel or web, cuts them into a narrower width, and trims off the rough edge of the deckle. In this case, subsequent trimming equipment such as winders, sheeters, trimmers and cutters are collectively referred to as secondary processing equipment. The winder rewinds the reel or web and is similar to the winder, but it can cut out a smaller size than the winder. There are different types of winders and winders available, which depends in part on the size of the roll being cut, including, for example, double-roll winders, Bobin winders, single-pass and multi-pass units. The sheeter accurately cuts the paper web into sheets; the cutter also cuts the paper web into sheets, but with lower precision. Sheeters and cutters are commonly used to cut large rolls. The trimmer cuts the large sheet into smaller pieces.

[0041] The winding is a roll-to-roll operation. Figure 2A and Figure 2B1, wherein a winder 50 cuts a full width large diameter paper roll 14 (FIG. 1) into rolls 55 of suitable size. During winding, a full width machine reel is transferred from the reel stand of the paper machine to an unwinding stand. From the unwinding stand, the paper passes through a web tensioning roller, an adjustable knife or slitter 56, an adjustable stretching rod 52, 54 (or roller) and onto a fiber or plastic core. A rewinding unit of two rollers 57 and 58 drives the winder. The stretching rod spreads the web after longitudinal cutting to prevent the web edges from interlacing. In this illustration, the web is cut longitudinally to form seven smaller strips, which are wound onto individual product rolls. The position of the knife 56 can be adjusted to cut strips of different widths according to the cutting pattern of the machine. The two outer rough edges of the reel are also trimmed off. Slitter winder apparatus are described in US Pat. No. 9,260,266 to Fohr, US Pat. No. 9,187,285 to Daul, and US Pat. No. 7,100,657 to Katoaka, which are incorporated herein by reference.

[0042] Figure 3 is an overview of the planner's insights for the flatbed industry of the present invention. Conventional pruning algorithms 72 focus on minimizing the number of primary rolls used to meet customer demands or orders, where the upper limit of demand constraints is relaxed, rather than minimizing pruning losses. Applying established policies, parameters and constraints (PPC), the profit maximization algorithm 70 generates a solution for the pruning application 76 operating the primary equipment and secondary equipment.

[0043] Utilizing the present invention, the analysis 74 provides the client with multiple recommendations including new insights about the business and gives recommendations about order quantities and sizes that they can make in order to achieve greater efficiency. The planner insights help identify the sizes and quantities that are more expensive for trimming in a particular batch. It determines the sizes that are impacted by the cost, which is used to create pricing strategies for specific products and sizes. Specifically, the insights are the size and for a specific size, the percentage of quantity to increase or decrease, which ultimately improves the efficiency of the plotting. Implementing these insights will improve the efficiency of each recommended trim by 25%, which is an insight for that batch.

[0044] The new insights will enable customers to develop pricing strategies based on quantity and size. Specifically, the new insights will identify specific sizes that result in more pruning losses because the right combination does not exist. Explore orders that can improve efficiency based on the current set of orders, inventory, and future orders. It will reduce the reliance on individuals for planning. Planner insights will improve productivity as it will reduce the manual costs associated with performing multiple iterations to achieve the desired pruning losses. Planner insights will generate solutions in a very short span compared to conventional pruning algorithms.

[0045] Planner Insights uses a column generation method based on the knapsack algorithm, the goal of which is to include the duality of both upper and lower demand constraints as well as information about losses and optimal usage. The objective function is defined to minimize losses instead of minimizing the total number of rolls used in a batch.

[0046] refer to Figure 4 In the pruning planning process shown in the flowchart in , in step 82, the order is fed to the pruning planning algorithm 80. There are two different types of orders, namely customer orders and inventory orders. All orders have the size (width, diameter, length) requested by the consumer, the promised delivery date, the quantity, and the final product type (grade). All orders are usually managed by an order management system running in the enterprise resource planning (ERP) or manufacturing execution system (MES) layer. The pruning planning algorithm is also connected to the quality control system (QCS) system of the paper machine 2 of Figure 1, where the quality parameters and defects of the machine are monitored, detected and controlled. Quality parameters and defect data are the main input sources for quality-based pruning. The pruning planning algorithm generates an optimized execution plan in step 86, in which the pruning losses of primary equipment and secondary equipment are minimized. For the primary slitting equipment 88 and the secondary slitting equipment 90, the execution plan is carried out through the MES interface between the equipment.

[0047] Figure 5 is shown with Figure 4 Detailed flow chart of the operation of the trimming plan algorithm 100 corresponding to step 80 of the papermaking process. Machine details 102 include machine master data for primary equipment or secondary equipment. For the papermaking industry, primary equipment includes winders, and secondary equipment includes, for example, rewinders, sheet presses, trimmers, extruders, and coaters. Machine details include, for example, the trimming edge of the equipment, the number of rollouts, the number of knives, the production rate, the capacity of a specific grade of product, the number of backings, weight handling constraints, and size handling constraints. Order details 104 include, for example, order size, grade, product name, specific quality requirements, shipping date, customer-specific needs, order quantity, and tolerances. Orders are managed by an order management system. Warehouse inventory 106 consists of information on various paper products managed by the management system, which are stored in warehouses at different locations. Warehouse inventory data includes, for example, reservations for specific products and unallocated and available inventory of different products and sizes. Reservations involve future customer-specific orders, which may be confirmed orders (99%). Some products are standard products, so orders can be fulfilled quickly. Warehouse managers can reserve some inventory to accommodate predicted future orders.

[0048] In operation, to create a trim plan for a specific product (grade), the user selects specific machine parameters from machine details 102. The user also selects order details 104 from the order management system. Machine details, order details, and inventory details 106 from available or unallocated inventory can be provided to the trim planning algorithm 100. The algorithm can adjust and reserve inventory if necessary. Customer specific preferences 108 such as size specific and overall tolerances, special areas, non-margins, quality parameters, stock roll preferences, secondary processing preferences, number of rolls per pack are provided as input to the trim planning algorithm. Finally, defect related information 110 from the QCS is provided as input to the trim planning algorithm.

[0049] The trim planning algorithm 100 is executed and generates solutions for four major components: (1) order quantity fulfillment 114; (2) cutting patterns in primary machines 116; (3) cutting patterns in secondary machines 118; and (4) inventory details with reservations 120. In general, (i) order quantity fulfillment includes fulfilling orders that must be completed within a tolerance range relative to the number of rolls, (ii) the primary cutting pattern of the primary machine includes the arrangement of slitter or knife for different roll sizes, which includes the original order roll size or mother roll size for secondary processing, (iii) the secondary cutting pattern of the secondary machine includes different slitter or knife positions for the original order roll size, which is generated from the mother roll by the primary cutting pattern, and (iv) the inventory details include the available roll sizes.

[0050] The pruning planning algorithm 100 also provides input to a recommendation system 112, which in turn generates improvement recommendations and suggestions for each of the above-mentioned parts 114, 116, 118 and 120. Based on the size combination and the given tolerance, the recommendation program will provide a group of sizes that will have additional tolerances to improve efficiency. The recommendation is based on the shadow price and range concepts in optimization. Generally, the generated suggestions include, for example: identifying the roll size with an additional quantity beyond the tolerance; (ii) identifying the roll size with the minimum quantity reduction beyond the tolerance, (iii) identifying the roll size that can be removed from the current batch to improve overall efficiency, (iv) identifying different inventory sizes and roll quantities.

[0051] Figure 6 The pruning planner algorithm 100 is described in further detail. Figure 5) is executed. Order details 130 are fed from the order manager system and in step 132, the orders are grouped based on the size, grade or product type and preferences of the order. The grouped orders are input to the formula of a mixed integer linear program (MILP) 134, where pruning loss is the objective. Machine details 138 and customer specific preferences 136 are inputs to the MILP. An internal call column generation is used to formulate the MILP pruning problem, whose pruning loss objective is subject to demand constraints. After execution, a solution is generated in step 140. In the next step, the solution is checked to determine whether it is optimal or suboptimal. If the solution is suboptimal, the solution is fed 146 to a knapsack combinatorial optimization problem, whose objectives are based on: (i) demand satisfaction (shadow price and maximum width); (ii) penalty for additional use of secondary equipment; (iii) use of optimal diameter of secondary equipment; and (iv) constraints on secondary equipment or primary equipment. In addition, the secondary equipment details are fed 148 to the knapsack algorithm. Through column generation, the modified objective in step 146 is provided as input in step 138. The loop is run until the solution becomes optimal.

[0052] When the solution is optimal, in step 144, the solution is rerun in the MILP with the modified group pattern with demand constraints and with pruning loss as the target. A solution 150 is generated. The solution contains: (1) pruning loss; (2) pattern details; (3) order fulfillment; (4) inventory details; and (5) secondary equipment allocation. A constraint report 152 is generated and generates two main outputs: one is the shadow price 156 for each size, and the other is the solution 154 of the MILP problem with equal constraints on demand. Based on the solution, an estimate 158 of the range is generated for a specific size with additional quantities. The shadow price 156 is fed to a recommendation system 160. The range of specific sizes is also fed to the recommendation system 160. The system generates the following recommendations: (i) possible addition of quantities; (ii) possible removal of quantities; and (iii) increase or decrease of inventory. Finally, the information from the recommendation system 160 is used to generate a solution for each recommendation using transaction or business tolerances. The solution has five main components, namely: trim loss, pattern detail, order fulfillment, inventory detail and sub-equipment allocation.

[0053] Solution formula

[0054] The standard or general formula for a pulp cutting problem starts with:

[0055] 1. The main scroll (fixed edge, giant scroll), whose width is D.

[0056] 2. m orders with auxiliary scrolls of width d1, d2, ..., dm.

[0057] 3. Each auxiliary scroll has a corresponding demand q1, q2, ..., qm.

[0058] A list of all meaningful feasible cut combinations (feasible combinations of required widths) associated with each pattern is constructed. The frequency of each required width of the auxiliary reel in the pattern is evaluated and assigned as the coefficient of the variable on the left-hand side of the inequality constraint. The requirements q1, q2, ..., qm are delegated to the right-hand side of the inequality constraint, and the sign ≥ (greater than or equal to) is placed between the left-hand and right-hand sides of the inequality constraint.

[0059] For the standard formula, j is the maximum number of meaningful possible combinations of master reels of width D. The goal is to minimize the number of master reel rolls to meet the needs of each order.

[0060] For this formula, f i,a is the number of times order i appears in the feasible combination Xa of the main scroll with standard width D.

[0061] The linear integer programming problem is thus: Minimize the number of rolls:

[0062] satisfy: And Xa>=0, an integer.

[0063] When the user solves the above problem, the user either uses the full enumeration pattern generation method or the column generation method. No upper limit is provided in the requirements of the column generation method. The reason is that the column generation method uses a knapsack algorithm, which uses the duality of the above requirement constraints in pattern generation. Duality is used in both objectives. When the user wants to have both an upper and lower limit, the standard or conventional knapsack method does not work because it always tries to minimize the number of rollers used, rather than minimizing the overall pruning loss. In addition, the current column generation method uses the knapsack algorithm based on the requirement lower limit. In actual practice, the user preferably wants to minimize the loss indirectly obtained by the standard or conventional method, but this is not effective because there is no requirement upper limit.

[0064] With the present invention, the user can minimize the loss within the upper and lower bounds of the requirements. This is achieved by modifying the problem with respect to both the knapsack objective and the method. Specifically, the unique objective function of the proposed pruning optimization algorithm contains a term related to the loss that is ultimately minimized. The objective of the knapsack algorithm in the column generation method contains the sum of the dualities of both the upper and lower constraints minus the loss. By adding two additional terms for the duality related to the upper and lower bounds, the term will eventually move to the solution to minimize the overall loss.

[0065] The new goal is to minimize the loss:

[0066] satisfy: The following conditions are met: and

[0067] Xa>=0, integer

[0068] q li＝ Minimum quantity

[0069] q ui＝ Maximum quantity.

[0070] Example

[0071] The techniques and benefits of the present invention are illustrated in the following example, where a paper manufacturer receives a customer order and applies planner insights. In this example, the winder is the primary equipment. The analysis provides novel insights into the business and generates multiple recommendations on order quantities and sizes that can be made in order to efficiently fulfill customer orders.

[0072] For this single batch trimming process, three main inputs are preferably used, including: (1) order details (roll size and quantity); (2) trade tolerances (at the individual order / size level and the overall batch / plan level); and (3) primary machine constraints and secondary machine constraints (such as trim, minimum trim, and number of rollouts). Specifically, trade constraints typically include allowances for over or under manufacturing quantities for each roll size or for the entire order, as well as overall allowances for over or under the number of rolls for the batch. Primary machine specifications typically include trim size, number of slitter machines, roll weight handling, minimum roll size, maximum roll size, number of rollouts, and additional losses and type of winder to be considered. Secondary machine specifications typically include the number of backings for loading the roll, number of stackings, trim size, number of slitter machines, roll weight handling, minimum roll size, maximum roll size, number of rollouts, and additional losses and type of winder to be considered.

[0073] List the orders and sizes in the table below. Optional orders are stock orders with future delivery dates. Optional orders do not need to be generated, or if generated, they can be partially or fully fulfilled, so quantities can be specified as zero or ordered. All other orders are mandatory orders.

[0074]

[0075]

[0076] The transaction constraints for each roll size are:

[0077] parameter Units of measurement value Overage per size Number of rollers 2 Underage per size Number of rollers 1 Excess of the entire batch Number of rollers 15 Shortage of the entire batch Number of rollers 15

[0078] The primary and secondary machine constraints are:

[0079]

[0080] The number of rolls is the number of rolls that the winder cuts in one pattern and is based on the number of knives in the winder. (For example, the maximum number of rolls is equal to the total number of knives minus 1). The first knife is located at the edge of the winder. The target minimum number of groups is the minimum number of groups for a specific cutting pattern when the solution is generated. The minimum set edge is specified by the customer to achieve efficient utilization of the set edge. The customer specifies the minimum pattern size width higher than the minimum set edge. For example, the standard size of the set edge is 500cm, and the user may want 470cm as the minimum set edge, so all patterns generated by the solution will have a set edge of 470cm or higher.

[0081] Based on the above constraints, Figures 4 to 6 The algorithm shown uses a knapsack algorithm to generate cutting patterns based on a column generation method. Specifically, the algorithm initially performs sizing considering trade constraints (individual and overall sizes) for each size and batch level and produces the following solution:

[0082] parameter Unit of measure (UOM) value Pruning loss ％ 0.43％ pattern quantity 13 Number of groups quantity 39 Shortage ％ 0 Overdose ％ 0

[0083] The pattern number is an index that identifies each pattern. The batching is then performed through the analysis and five recommendations are generated (depending on the configuration). Each recommended solution comparison generates a solution. The solutions for the corresponding recommendations are shown below.

[0084]

[0085] (Qty is quantity)

[0086] For this example, five solutions are generated, each with recommendations that are the minimum succession of tolerances. In solution 1, the recommendation for fulfilling the entire order set forth in the first table above is to manufacture 1 additional roll for each of the sizes 103 cm, 133 cm, 160 cm, and 165 cm. If solution 1 is implemented, the trimming loss is 0.18%, which is the total trimming loss percentage. (For example, a trimming loss of 1% corresponds to an efficiency of 99% of the cutting pattern). The solution has a combination of 12 possible cutting patterns suitable for the overall width (seam size). The number of groups (42) is the total number of reels (seam size) used to fulfill all orders of different sizes. An under-volume of 2.82% refers to the percentage of the number of orders that is less than (lower than) the entire batch, while an over-volume of 9.15% refers to the percentage of the number of orders that is more than (higher than) the entire batch. Trimming losses, under-volumes, and over-volumes are parameters that measure the effectiveness of a solution. A person chooses a solution to operate primary equipment and secondary equipment to fulfill orders.

[0087] The foregoing describes the principles, preferred embodiments and modes of operation of the present invention. However, the present invention should not be construed as being limited to the specific embodiments discussed. Therefore, the above embodiments should be considered as exemplary rather than restrictive, and it should be understood that variations may be made in these embodiments by those skilled in the art without departing from the scope of the present invention as defined by the following claims.

Claims

1. A method for generating an optimal trimming pattern for trimming raw rolls and / or sheets to fulfill flat stock and / or customer orders, the method comprising: (a) Receive customer order specifications; (b) receiving preliminary machine specifications; (c) receiving secondary machine specifications; (d) receiving warehouse inventory specifications; (e) receiving transaction constraints; (f) generating a solution for the following parameters: (i) order quantity fulfillment, (ii) primary cutting pattern of the primary machine, (iii) secondary cutting pattern of the secondary machine, and (iv) inventory details, wherein the solution is generated taking into account the received transaction constraints; (g) execute batches and generate recommendations; (h) generating a modified solution for the parameters in step (f) using the revised trading constraints derived from the recommendations generated in (g), wherein steps (f), (g) and (h) are performed using a knapsack algorithm that employs a column generation method, wherein the knapsack algorithm has an objective function for minimizing pruning loss and the objective of the knapsack algorithm includes duality of both upper and lower demand constraints and information related to pruning loss and optimal usage; and (i) Operate the cutting equipment by: receiving reels or sheets of material to be cut; configuring the cutting device using the modified solution generated in step (h); as well as The configured cutting device is operated to cut the reel or sheet of material into a plurality of smaller reels or sheets.

2. A method according to claim 1, wherein (i) the order quantity fulfillment includes fulfilling orders that must be completed within a tolerance range relative to the number of rolls, (ii) the primary cutting pattern of the primary machine includes the arrangement of slitter or knife for different roll sizes, and the roll size includes the original order roll size or mother roll size for secondary processing, (iii) the secondary cutting pattern of the secondary machine includes different slitter or knife positions for the original order roll size, and the original order roll size is generated from the mother roll by the primary cutting pattern, and (iv) the inventory details include available roll sizes.

3. The method of claim 1, wherein the recommendations generated in step (g) are selected from the group consisting of: (i) identifying roller sizes that have additional quantities that are out of tolerance; (ii) identifying roller sizes that have minimum quantity reductions that are out of tolerance, (iii) identifying roller sizes that can be removed from the current batch to improve overall efficiency, and (iv) identifying different inventory sizes and roller quantities, and their mixtures.

4. The method of claim 1, wherein the modified solution generated in step (h) includes an option for the user to select to replace the initially received trade constraints or inventory specifications.

5. The method of claim 1, wherein the flat stock comprises paper, rubber, plastic or metal.

6. A pruning system, comprising: A computer device (40), wherein: (a) Receive customer order specifications; (b) receiving preliminary machine specifications; (c) receiving secondary machine specifications; (d) receiving warehouse inventory specifications; (e) receiving transaction constraints; (f) generating a solution for the following parameters: (i) order quantity fulfillment, (ii) primary cutting pattern of the primary machine, (iii) secondary cutting pattern of the secondary machine, and (iv) inventory details, wherein the solution is generated taking into account the received transaction constraints; (g) execute batches and generate recommendations; (h) generating a modified solution for the parameters in step (f) using the revised transaction constraints derived from the recommendations generated in (g), wherein the computer device (40) is configured to perform steps (f), (g) and (h) using a knapsack algorithm that employs a column generation method, wherein the knapsack algorithm has an objective function for minimizing pruning loss and the objective of the knapsack algorithm includes duality of both upper and lower demand constraints and information related to pruning loss and optimal usage; and A cutting device (50) for cutting a reel or sheet of material into a plurality of smaller reels or sheets of material, wherein the cutting device is configured to receive the modified solution generated in step (h).

7. The trimming system of claim 6, wherein the cutting device is selected from the group consisting of a winder, a rewinder, a sheeter, a trimmer, a cutter, and mixtures thereof.

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