Page 24 - MetalForming August 2016

Smart Part Nesting
machine requests a nest, any new cri- terion is included in the new optimal solution for the next machine cycle. A new part is scheduled and produced during the next machine cycle; the schedule changes, so all available resources are utilized to make the right parts to support the change.
Savings in Manpower, Time and Material Utilization: An Example A value stream can show a number of different variables that express time and value. For now, let’s be concerned with savings and transit time for each operation. The accompanying table, Nesting Costs: Old Versus New Para- digm, compares the new and old par- adigm for a company using three machines and accumulating $5,000,000 in nested raw-material costs each year. To estimate possible savings in order entry and nesting time, deter- mine the number of employees used for these functions each day. Savings will be 100 percent of these costs, as
order entry and nesting becomes com- pletely automated.
It is important to note that employees freed from traditional nesting tasks will be used, at least in part, for continuous improvement. Additional savings on their salaries will result from benefits of cost improvements that they may imple- ment. In these estimates, it is assumed that continuous improvements will reduce annual costs by a dollar amount greater than the salaries. Therefore, sav- ings shown are the full salaries.
The elapsed time from availability of new CAD parts to completed part programs includes not only program- ming time, but also the wait time from release until a part is programmed. For example, 100 parts released at the beginning of a day and available to be nested by the morning of the next day results in a transit time of one day. The same method can be used for nesting transit time—the elapsed time from when parts are available to be nested until they are run on the shop floor.
Speed, or reduced transit time, allows for production of only the parts needed next, which reduces work-in- process (WIP) inventory. In slower shops, unplanned events create further delays and increase costs. Rapid-transit shops respond to unplanned events in the next machine cycle, meaning no additional delays and chaos caused by unplanned events. Take, for instance, a defective part that must be remade. Significant delays in responding to this hot part will compound problems. The press brake used to bend the parts may have to move on to a different job with a new setup, and then incur an addi- tional setup later on to remake the hot part. Responding quickly to unplanned events ensures reduced setup time, smooth flow, less WIP inventory and on-time delivery. MF
Article adapted from a white paper, 5th Generation Rapid Transit Time Nest- ing Systems, provided by Optimation, Blue Springs, MO; tel. 877/827-2100, www.optimation.com.
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22 MetalForming/August 2016
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