【Introduction to Sheet Metal Design Technology】Technology to Improve Yield with Forward-Looking Nesting
About the innovations in material handling (nesting) at our company.
Nesting refers to the process of combining and arranging multiple parts from steel materials. Its purpose is to reduce material waste. Specifically, how can we improve material yield and achieve efficient machine operation? In the era when turret punch presses were the main machinery, steel was purchased in sketch material sized to fit each part, and it was common to process each piece individually. However, as laser-turret punch combination machines became the mainstay, the method shifted to purchasing standard-sized materials for processing. Consequently, CAM software transitioned from AP100 to Dr. ABE, giving rise to the culture of nesting. However, using standard sizes for each product as in the past resulted in poor yield, leading to increased material costs and a tendency for product costs to rise.
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In response to changes in the times, software is also evolving, and a fundamental change in approach has become necessary. In our company, the delivery times for products vary depending on the customer, and to take advantage of this, we are outputting processing information for one month ahead in CSV format from our production management system. We are eliminating categories by customer and consolidating based on steel type and plate thickness, and by nesting these, we are working to improve the yield of standard sizes. As a result, it has become possible to reduce material costs. However, it is necessary to identify the disparate products, and a new initiative for this purpose has become essential.
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Relying solely on the method of summarizing based on the steel type and plate thickness from customer orders makes it increasingly difficult to improve yield and productivity. It is now a pressing challenge to analyze past production history and implement forecast production for general-purpose parts by integrating the production management system with RPA. Additionally, we are also developing devices for automatic identification of blank materials without relying on human intervention.
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Company information
Since our establishment in 1964, we have been designing and manufacturing custom lockers, office furniture, and steel furniture for over half a century. We excel in collaborating with customers from the design stage, providing products through OEM and ODM, and creating made-to-order lockers. Our strengths lie in our extensive design know-how and processing achievements, allowing us to achieve consistent production and completion in-house due to our knowledge of sheet metal and abundant equipment. The original lockers developed from our experience vary widely and possess unique characteristics that differ from other companies' catalog products, including usability, durability, and design. Our unique product range, including valuable item lockers, smart lockers, sports lockers, work lockers, and mailboxes, is a confident creation that aggregates feedback from our customers. We can provide not only standard products but also customized made-to-order items in various sizes and colors quickly and at low prices, thanks to our in-house design, sheet metal processing, painting, assembly, and production system, along with our quality assurance system. Additionally, our production management system and the manufacturing network in Higashi-Osaka enable us to realize products that include components beyond sheet metal. By becoming your partner with our ISO-certified management system, we can assist in product development and sales expansion.