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03 – Creation of an Optimized Cutting Plan

Immediately after the completion of the Review process, and at the same station, the operator or supervisor can submit the defect map to an optimising function. This function utilises stored rules based on product and customer requirements for the final small rolls, such as maximum and minimum roll lengths, the number of pieces per roll, the number of defects per roll and a points system. 

Rapid Optimisation

Within seconds of submitting the reviewed defect map, the system generates a cutting plan designed to maximise yield from the batch. The on-screen report provides detailed metrics, including:

  • Percentage yield
  • Number of rolls
  • Percentage of scrap
  • Number of short pieces (typically none)
  • Additional relevant data

Iterative Improvement

If the initial yield is below requirements, the defect map can be re-reviewed, adjustments made and a new cutting plan generated within seconds to improve results.

Profit Generation

This stage transforms system-generated data into profit, significantly contributing to the overall return on investment. Every percentage yield improvement adds the same percentage of revenue to profit line. The success of this stage relies on the accurate, consistent and validated data produced by a reliable and accurate defect map.

The optimised cutting plan ensures that the final small rolls meet commercial and customer standards, maximising efficiency and profitability. It also allows decisions to be made on better utilisation of substandard rolls. 

Back to the Four-Step Process Overview

On to step four - reduce waste, increase yield and profit