Cutting System Residual-Part Flow Control by Reuse Forecasting
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Solution Overview
Problem
Existing systems fail to efficiently utilize leftover materials during cutting processes, leading to increased storage needs and reduced reuse within production facilities due to reliance on individual expertise rather than systematic approaches.
Innovation Solution
A system comprising a cutting machine, material storage, and a computerized database management system that classifies cutting jobs and leftover parts, optimizing their reuse based on past orders and material properties, with automated decision-making for storage or recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a systematic automated approach is implemented to increase material utilization, then material utilization improves, but device complexity increases
Solution Approach 1:
The system segments cutting jobs into different classes based on material type, product type, and order frequency. This classification divides the complex problem of material optimization into manageable categories, allowing automated decision-making without requiring overly complex algorithms for every possible scenario.
Solution Approach 2:
The system performs preliminary classification of cutting jobs and pre-calculates optimal material usage strategies based on historical data. By preparing and storing classification rules and decision criteria in advance, the system reduces real-time computational complexity while maintaining high material utilization.
2Productivity
If computational algorithms are made more sophisticated to optimize material flow, then material utilization improves, but computing power requirements increase
Solution Approach 1:
The computational problem is segmented by classifying cutting jobs into discrete categories (material type, product type, frequency). This allows the use of simpler, faster lookup-based algorithms rather than complex real-time optimization, reducing computing power requirements while maintaining effectiveness.
Solution Approach 2:
The system uses historical data and patterns from past cutting jobs to create representative models and decision rules. Instead of performing complex calculations for each new job, the system copies and applies proven decision patterns from similar historical cases, significantly reducing computational effort.
3Productivity
If leftover parts are retained in storage for potential reuse, then material utilization improves, but storage requirements increase
Solution Approach 1:
The system dynamically adjusts storage decisions based on real-time factors including current storage capacity, upcoming order requirements, and material classification. Rather than using fixed retention rules, the system adapts its storage strategy to balance material reuse potential against available storage space.
Solution Approach 2:
The system incorporates feedback from storage status and order patterns to adjust its material retention decisions. When storage is full or when historical data shows certain materials are rarely reused, the system adjusts its criteria for retaining leftover parts, optimizing the balance between reuse potential and storage requirements.
Data Source
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AI summary
The system is designed to process a large number of different cutting jobs at irregular times, essentially sequentially. First, a processing part is selected from the material storage database. Then, the usable parts to be produced for the current cutting job are arranged on the processing part in an optimized manner, so that the processing part is divided into a contiguous area with usable parts and a contiguous remaining part without usable parts. Next, a material flow control command is generated for the remaining part. The material flow control command can assume at least a first state that signals storage and a second state that signals recycling. The material flow control command is based on a reuse forecast of the remaining part for a defined <unftszeitraum ab Zeitpunkt des aktuellen Schneidauftrags. Dabei werden die ausgeführten Schneidaufträge berücksichtigt.If the reuse forecast is above a threshold, the remaining part is placed in the material warehouse.