For years, efforts to maximize the efficiency of the punch press process were viewed as being comparable to trying to grab the unattainable brass ring. Tooling constraints combined with inconsistencies in order size and dimensions of parts were responsible for fueling such skeptical thoughts.

Static nesting, the method of grouping an order of different sized parts on one batch of sheets, was long considered the most effective tool for optimizing punch production. This method often works well with one-time large orders. But it creates problems when design changes are made; presenting fabricators with the dilemma of either re-nesting the order or loading up their inventory with unnecessary parts.

Today, the emergence of dynamic nesting has made such methods fairly antiquated. Software-based dynamic nesting optimizes punch press production by using mathematic algorithms to group dissimilar jobs on the same sheet. Tool availability and the capability of the machine are just some factors take into consideration by punching software systems when determining the best method for optimizing production.

By making nesting decisions based on order priority and material inventory, automatic nesting software is able to appropriately address the production needs of that particular moment. In turn, this enhances the efficiency of a fabrication shop by reducing wasted material and the production of unnecessary inventory.

Here are examples of features offered by some of the better quality nesting fabrication software:

Job Tracking: Optimizes nesting by automatically tracking part quantity in conjunction with the scheduling of orders.

Inventory Management: Maintains sheet consumption inventory in real-time. Also maintains a graphical sheet history analysis with details such as length, width, thickness and material grade. This feature also includes a cost reporting status based on factors such as area, weight and cost of sheet.

Time and Cost Analysis: Via an integrated model, calculates the cost of a part based on factors defined by the user, such as machine recovery rate. Also provides an order process time that is based on the projected feed rate, machine acceleration and material type among other parameters.

Automatic Reporting: Provides comprehensive job reports with details such as tool usage, material yield, time estimates and automatic job cost feedback.

Automatic Tooling: Eliminates the need to manually select the appropriate cutting tool to use on a particular part.

The benefits offered by nesting software are not limited to punch machines systems. Laser cutting, shearing and plasma cutting are just a few types of manufacturing equipment where the use of nesting software has been proven beneficial.

The advent of automatic nesting has given fabricators the ability to take a more practical approach in reducing unnecessary production costs. While nesting software systems can be a valuable asset for fabricators, they can also prove to be a liability if the appropriate research isn’t taken before making a purchase.

Cornel S TerreBlanche, marketing coordinator of SigmaTEK, is the author of this article about automatic nesting software, patching software and fabrication software. SigmaTEK is a Cincinnati-based company providing automatic nesting software solutions to enhance efficiency and profitability for sheet metal fabricators through its CAD/CAM software, SigmaNEST.