Attribute-Based Scheduling & Trim Optimisation in One Application
Greycon’s opt-Studio contains attribute-based scheduling, thus eliminating time- and space-consuming material structures. The system is cognisant of sheet-like attributes like thickness, diameter, length, area etc. and performs all unit conversions automatically and transparently. opt-Studio therefore handles situations such as lamination, slitting, joining width-wise (“tarp”) out of the box.
The same system also contains trim optimisation capabilities, therefore recognises the many-to-many relationship between physical entities (like reels) and logical ones (orders). For complex situations, such as extruders with middle knives, X-Trim can also be used as the trim optimisation engine.
The optional Available-to-Promise / Capable-to-Promise (ATP/CTP) module can provide real-time response to the external order entry system, promising accurate delivery dates.
Greycon Converting Case Studies
The Stock Conversion Module provides the functionality to address situations where material to satisfy orders can be sourced from any mixture of primary production / semi-finished inventory / finished inventory.
Stock can be of different types:
- Primary conversion for jumbo reel stock
- Parent reel via exact-match, rewinding, sheet cutting
- Sheet stock via exact-match, guillotining
The user may control the relationship between orders and stock items:
A single order may be sourced from a mixture of sources:
Stock reels may have three different types of faults:
- Normal faults, which are areas that cannot be used at all:
- Hi-Lo-Hi faults, which typically are areas of large caliper variation and therefore are exclusion zones for slitter knives:
- Full-width faults:
More complex scenarios, including film remounting are also possible.
In many winders / slitters there are anvils that are pre-configured with the knives. The constraints associated with these anvils are defined in the following form:
The weighting in relation to the knife changes is for guiding the optimisation in terms of the relation between the cost (time) of an anvil change compared to a single knife movement.
Anvil & Knife Change Minimisation
The two screenshots below show the effects of applying Greycon's advanced anvil and knife change minimisation to a solution:
Anvil changes have been reduced from four to two and the knife changes from 18 to 14.
Multiple Slitter / Winder Support
The system allows for multiple slitters and winders. Each individual pattern can be assigned to a specific winder / slitter. Anvil and knife change minimisation can be applied to each winder / slitter's schedule.
Some of Greycon's Converting Industry Clients
Loparex BV manufactures and supplies silicone release liners, silicone-coated papers, and blown film products. The company offers extrusion coated and siliconized release papers; and silicone coated polyethylene, polypropylene, polyester, and polystyrene films.
MACtac is a global company developing and producing innovative self adhesive solutions aimed at various markets: medical, automotive, electronics, building and construction, glass industry, labeling and packaging, decoration and visual communication.
Elopak Denmark A/S manufactures and markets packaging systems for liquid foods including milk, juice, water, wine, and soups. In addition, the company also provides carton and plastic-based packaging systems for liquid food and nonfood products.
Scandstick AB develops and manufactures high performance self-adhesive label stock materials for the label printing industry. The company offers roll products, including paper, films, thermal, thermal transfer, direct thermal, synthetics, and office-A4; and tickets and tags.