Scrap rate on the fascia line has been reduced 25% in just four months. “Tens of thousands of dollars can be saved with even a few percentage points decrease in scrap levels.”
Launching new facilities presented Otis with new challenges. SigmaNEST® was selected to drive productivity and reduce waste.
People moving systems
4 Trumpf 2020 punch presses and a Cincinnati shear machine Skeleton material projections were 19.2% based on 5.5 million pounds of material per year Mazak laser cutting and robotics, combined with SigmaNEST®
MULTIPLE MACHINES – SINGLE NESTING SOFTWARE
The company’s Nogales, Mexico operations (three facilities) drives New Generation Door (NGD) production. The requirements were: Nesting software (compatible with all cutting/punch machines) to automatically create tight, efficient nests to reduce scrap Interface with their other business systems Continually monitor material usage SigmaNEST software and SigmaTEK Services Group were the answer. SigmaNEST adapts to even the highest level of automation with advanced modules and custom enhancements added by SigmaTEK Services Group. SigmaTEK automated manual CAD work typically done before nesting. Otis wanted ‘On Demand’ functionality allowing files to be created in the MRP; then simply open SigmaNEST or SimTRANS™ (SigmaNEST / MRP interface) and push a single button.
Fabricating the highly customized parts of the deco line required different material types and thickness such as stainless steel and brass, including costly satin/mirror finishes. Minimizing skeleton material was vital and nesting had to be tight while maintaining the highest part quality. With the goal of little if any human intervention, nesting configurations had to be automatic. Soon after production began, scrap levels were slashed to 13%.
The fascia line uses a Trumpf 2020 punch press. With assistance from SigmaTEK Services Group, production went live that week. Scrap rate on the fascia line has reduced 25% in just four months. “Tens of thousands of dollars can be saved with even a few percentage points decrease in scrap levels,” stated Otis Industrial Engineer, Jesus Valenzuela.
Achieve higher automation levels for the deco and fascia lines by merging processes into a single process flow. Implement SigmaNEST and related automation at other facilities. In addition, Valenzuela mentions the ever improving scrap levels and their new expectations. “We’d like to see a material utilization greater than 95% for the entire facility.”