Every percent counts when it comes to slashing production costs. Taking advantage of the latest nesting software helps companies better utilize material, and, in turn, remain competitive in a global market.

Figure 1

Software sold in modules is the best way to provide a solution. The provider's sales manager should study manufacturing operations, then offer a customized solution.

One approach fabricators are using to trim costs is by making better use of their raw materials, which can consume 50% of operational costs. To that end, many shops are exploiting nesting software to reduce material waste and realize substantial savings. They've found that improving nests even by 5% can minimize the raw material needed to complete a job and, thereby, slash production costs — as illustrated in Figure 1.

Better material utilization also makes a company more competitive in a global market. For instance, companies cutting 500 tons of steel per month can save about $250,000 with more-efficient nesting algorithms. One company recently used the economic benefits of nesting software to prevent moving its production to China.

The focus of nesting software is maximizing material utilization and improving processes and flexibility. As the technology matures, it not only provides machine code, but it also handles all multifunctional aspects of the fabrication process, whether for laser, waterjet, plasma, oxyfuel, or punch.

When purchasing a CAD/CAM nesting software, shops should address four points:

1. Superior nesting algorithms --Programmers continually develop algorithms that allow parts to be nested as tightly as possible, using the minimum amount of material. The user has full control of the material yield, including the ability to nest parts within parts. Without this, inside contours of geometries become waste.
2. Motion optimization - Machine motion can be controlled to perform common line cutting, bridge cutting, and variable quality, saving time and consumables. Even though tough decisions are made, as in punching between motion optimization and part quality, SigmaNEST software from SigmaTEK, Cincinnati, OH, lets users make these decisions with automatic or manual NC programming.
3. Programming time - The ability to import DXF, DWG, CADL, IGES, and HPGL lets programmers import from almost any CAD program. Automatically unfolding and importing parts from Solid Edge, Solid Works, and Inventor provides a seamless integration, which saves time and decreases part-geometry errors. Once geometry is imported, the nesting task is defined and the NC program is produced with little effort. Simplified programming allowed one user in Florida to reorganize one of his four programmers and still increase throughput by 30%.
4. Management production information - SigmaNEST has an open architecture that allows users to access code and customize cost and quoting information. Once this information is defined, accurate part quotes are quickly generated.

Technology is evolving to meet challenges faced by fabricators. SigmaTEK has developed features such as the ability to create batches of various jobs and nest them by material, including direct interfaces with popular solid-modeling software, the capability to save complete turret tool configurations, and rotational control of parts.

Some agree the best method of evaluating a nest is by sight, not the focus on unattainable sheet-yield percentages. Evidence however, has shown material yield is a key factor in manufacturing productivity. Recent studies by several major manufacturers found that 5% of material savings can translate to thousands of dollars in savings. This small change in yield cannot be visualized.

Software suppliers are filling the need of the industry. The question is which software supplier should a fabricator choose.

Glenn Binder, SigmaTEK's director of marketing and sales, suggests seeking a solution provider making use of software, rather than a software provider. He says software sold in modules is the best way to provide a solution. Binder says the provider's sales manager should study the manufacturer's current operation, define its needs, and only then offer a solution customized to its business.

While evaluating software, ask about return on investment; otherwise, there is no need to upgrade to a new system. In some cases, increased material utilization alone can justify an upgrade. There are other options available to increase productivity and efficiency. The ability to electronically store and track remnant material can have a profound effect in a shop.

By implementing remnant nesting, a jobshop in Alberta, Canada, roughly halved a $300,000 annual inventory. The decrease in capital tied up in the dust-collection department allowed for more efficient shop operation. This company found itself against a wall to please a customer. It succeeded when faced with cutting 55 tons of steel in a 3-hr time period.

It is easy to quantify a return on investment with solid numbers. It is more difficult, however, to quantify a customer that trusts a job can be completed correctly on time. Legacy software may not have been able to complete this task. This shop is now enjoying substantial profits and paid off the machine and software in only 18 months.

Some of the recent buzzwords in the industry include yield improvement, motion optimization, integration and automation, and range of solutions. When faced with today's manufacturing challenges, choose software on the forefront of development and technology. Look for a company that continually improves products to help users survive a tough economy. Some newer developments in nesting software include common line cutting, auto-dynamic nesting, and feature avoidance. Each of these features was designed to save users time and money.

As the industry continues to grow, expect to see advancements in NC programming and the use of .net technology. With many companies implementing lean-manufacturing practices, look for the CAD/CAM industry to respond in kind with new functions such as increased automation and lights-out manufacturing.

Edited from material provided by SigmaTEK Corp., Cincinnati, OH. For more information, contact Scott Grindstaff at (513)674-0005 ext. 130.