Semi-Automatic Nesting and Lean Problem Solving in a High-Mix, Low-Volume Production Environment

Abstract

Nesting in manufacturing involves arranging parts to be cut in the most efficient way possible to minimize the material left over after being cut. While many commercial software solutions have optimization algorithms that can do this efficiently, complex manufacturing processes in high-mix-low-volume (HMLV) environments make it difficult and time consuming software to implement the software. This paper describes a solution built for a HMLV company to automate significant portions of the nesting process while maintaining enough human input to deal with complexity, reducing their time to nest jobs by 83% and the time to re-nest jobs in the case of a production schedule change by 95%. We focused on using lean principles as a time-saving strategy rather than a direct cost cutting strategy in order to improve quality of life for operators while improving customer service. Initial iterations of the solution focused on complete automation of the nesting process with one click by the operator, but variability and complexity in the manufacturing system required a more semi-automatic solution that allowed for operator input but in a much easier and faster way than the initial state. This solution building is an example of using the A3 lean problem solving process to align stakeholders and rapidly experiment/iterate a solution until it achieves desired performance.