Nesting in OnRamp

Nesting is the process of efficiently cutting parts from a flat piece of raw material in an arrangement that achieves the best possible material utilization, which minimizes waste.

Nesting Setup Workflow

Before setting up a nest, enter data on the following screens:

  1. Use Part Master [S1009] to set up the raw materials that are nested as well as the parts that are cut from these raw materials.

  2. The dimensions of both the raw material and the produced parts based on their Commodity Code.

  3. You can define alternate parts to an existing part on the Parts for Substitution [S1011] screen.

  4. A BOMClosed A bill of material, or BOM, is a list of parts required to build another part. is required for any manufactured part. For more information, see Manage BOM .

  5. Nesting work orders require that parts have inspection steps assigned to be released.

  6. Once all the above items have been added, you can add the nest. Nests can then be assigned to nest groups.

Releasing a Nested Work Order

To assist you in releasing a nest to a work center, OnRamp has a suggested nesting MRP screen to help calculate planning requirements for the nested parts. This plan can then be exported to be used by the nest.

For more information, on the Suggested Nesting MRP [S2064] screen, see Generate Suggested Nesting MRP.

Once the MRP is run, you can then issue and release the nest work order to the shop floor.

Scheduling Nests

Nest Scheduling allows you to organize and map your nest groups in a way that maximizes the efficiency of nested operations. To do this, you must:

  1. First, define the schedule groups.

  2. Next, set up the work center availability.

  3. Finally, setup the nest schedule groups.

Defining Schedule Groups

A schedule group is quite simply the group or work centers that will be scheduled together. Schedule groups are created on Shop Schedule Group [S2595].

When adding a Nesting schedule group, set the Type to Nest.

For information on adding schedule groups, see Manage Shop Schedule Groups.

Setting up Work Center Availability

The work center availability is the number of hours per day that the work center is available to perform operations. To do this, you have to:

  1. Define which shifts to use.

  2. Link the shifts to the work center.

  3. (Optional) Fine-tune availability, scheduling, cut settings, and assign special capabilities to work centers.

  4. (Optional) Alter shift capacity.

Defining Shifts

Shifts are setup on Shift Master [S2470]. When setting up a nesting shift, toggle Used for OEE to Yes.

For information on adding shifts, see Manage Shifts.

Linking Shifts to Work Centers

With the required shifts created and the running times set, you have to link these shifts to the correct work centers. This is done on Work Center Availability [S2809].

For information on adding shifts, see Manage Work Center Availability.

Fine Tuning

You can fine-tune the work center availability, the scheduling accuracy, and the cut settings. These actions are performed on the Work Center Master [S1019]. Here, you can:

  • Include the average time it takes to switch to the next group and the time it takes to load and unload plates. These impact availability and scheduling accuracy.

  • Include a cut speed factor to account for work center cut speed difference or material difference, such as the different speed required to cut through a thicker sheet of metal.

For information on editing work centers, see Manage Work Centers.

Fine Tuning Notes

  • You can also update the First Plate and Sched Delay Per Plate when adding the work center to the schedule group on screen 2595.

  • Use Parameter Management [S2663] to manually add speed variables for work centers based on material thickness. These parameters must be within the Param ID of WC_SPEED_FACTORS.

  • If a parameter is added along with a cut speed factor, then the parameter value takes precedence.

  • Special Capabilities are Local Codes that are created by you on screen 1502. These special fields are set on work centers and part routing. When scheduling a part where a routing step has the Capability Required, the work center must have this Special Capability to be used.

Altering Shift Capacity

You can also define any changes in shift capacity. For example, if you have a shift where you only have one staff instead of two working on the weekend. This is done on Work Center Availability [S2809].

Scheduling the Nest Groups

Once the setup is complete, schedule the nest group. This is done on Nest Scheduling [S2819].

For information on scheduling the nest schedule groups, see Schedule Nest Group.

Reporting on Nests

After releasing a nested Work Order, you can monitor the production progress using various Reports. This allows you to identify and address any issues. The following is a list of some of the most useful and used screens and reports for nests:

  • The Nest Group Inquiry and Comments Modification [S2148] screen displays your released nested work orders and allows you to add comments
  • The Report Nest [S1678] screen records the progress of nested Work Orders and records any defects encountered. For more information, see Report Nested Work Orders.

  • The Suggested Nest Orders by Commodity Codes and Thickness [R3168] report displays possible nest orders by commodity codes and the thickness of the plate.

  • The Gateway Queue by Nest Group [R4208] report provides insight into the status of the Nesting Gateway.

  • The Work Order Inquiry [S1100] screen displays a comprehensive profile of all Work Orders.

Nest Schedule Reporting

To view your nest schedules, you can use:

  • Schedule Nests by Schedule Group [R4784] – This report is a comprehensive to-do list for the work center operator.

  • Work Center Nest Schedule [S2660] – This screen presents a real-time view of the nest schedule.

Implementing shop monitors that are running the nest schedule dashboard can improve usage by displaying the real-time statistics for the nest, including:

  • the current job, status, and time

  • the upcoming details and required material

  • the overall schedule status