Production Floor Optimization for 3D Product Nesting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current software solutions fail to optimize the production floor workflow for three-dimensional products, neglecting parameters such as due dates, workforce availability, machinery utilization, and the formation of remnants, leading to inefficiencies in material use and production processes.

Innovation Solution

A software system that integrates input parameters like job data, due dates, product design, and production floor resources to compute an efficient production plan, including optimal nest design and resource allocation, using algorithms to weigh the importance of various factors and optimize material utilization, labor costs, and machine run-time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If multiple jobs are combined into a single nest to save material, then material utilization improves, but labor time for separating items increases

Engineering Contradiction:

Improvematerial wasteVSAvoidlabor time for separation

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The system segments the nesting problem into multiple levels: first segmenting jobs by due date and resource requirements, then segmenting the nest into regions for different jobs. This allows material optimization while minimizing mixing of different job items, reducing separation labor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts the degree of job mixing in nests based on real-time parameters such as due dates, resource availability, and material savings potential. The optimization is not static but adapts to changing production conditions to balance material utilization against separation complexity.

Inventive Principle:

Principle #15Dynamics

2Loss of substance

If the production plan optimizes for material utilization, then material waste reduces, but production time may increase due to complex optimization

Engineering Contradiction:

Improvematerial wasteVSAvoidproduction speed

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The system performs preliminary optimization of nests before production, pre-calculating optimal arrangements that balance material utilization with production time constraints. This advance planning prevents excessive optimization time during actual production while achieving material savings.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes optimization parameters dynamically, adjusting the weight given to material utilization versus production time based on job priorities, due dates, and resource availability. This allows the system to find optimal balances rather than always maximizing material savings at the cost of production speed.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If cutting machines are loaded once with large blocks to speed up cutting, then cutting efficiency improves, but remnant waste increases

Engineering Contradiction:

Improvecutting speedVSAvoidremnant waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The system applies nesting optimization to arrange multiple job items efficiently within each large block loaded on the cutting machine. By nesting smaller items around larger ones and optimizing the layout, it maximizes material utilization from each block while maintaining the efficiency benefits of batch cutting.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Productivity

If the system considers multiple parameters (due dates, resources, material utilization), then production efficiency improves, but system complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidsoftware complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system integrates multiple functions into a single unified optimization platform that handles job scheduling, nest design, resource allocation, and remnant tracking simultaneously. This multi-functional approach manages complexity by providing a comprehensive solution rather than multiple separate systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10310492B2Multi-dimensional resource optimization in the manufacture of three-dimensional elements background

Publication Date: 2019.06.04 PLATAINE

AI summary

The invention provides a computerized method for optimization of efficiency of a production floor producing three-dimensional products using two-dimensional cutting machines, the method comprising:a. receiving input parameters comprising job data, due dates, product design data, production floor resources available and inventory data;b. maintaining in memory manufacturing rules and objectives;c. assigning relative weights of importance to the input parameters and to the manufacturing rules and objectives;d. computing, based on the input parameters, on the manufacturing rules and objectives and on the relative weights of importance, a production floor work plan schedule;e. determining whether the schedule is efficient in utilization of materials and resources available; if so, outputting the production floor work plan schedule;f. if the computed production floor schedule is determined to be inefficient, repeating steps (d) and (e) until it is determined to be efficient.A system for optimization of a production floor work plan schedule is also disclosed.