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CHAMPCUT

An Online Yield Optimizer of Roll Material

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Your customer requests rolls in various widths?

Then you need to cut your mother rolls into smaller cuts on a slitting machine.
This gives rise to the problem of fulfilling customer demand by utilizing as little material as possible from your mother rolls. See Examples Below!

What We Offer

What We Offer

Our Workflow

Create Production Order

A production order combines information on customer demand and the production machine. This can be done collaboratively in teams working on a dataset in the cloud.

Create Cutting Plan

A cutting plan is the information how you want to cut your mother rolls into smaller cuts. The challenge is to waste as little material at the sides as possible. You can define the cutting plan manually free of charge. As this operation is complex, you can use our dedicated solver, which saves your working time. If your are happy with the result, you can purchase the cutting plan.

Refine Cutting Plan

The cutting plan can be further refined by adjusting the sequence of cutting patterns or the order of cuts within one cutting pattern. This can be done by drag and drop or using a solver free of charge. The solver will try to minimize the number of knife positionings necessary at the slitting station.

Convey To The Shopfloor

Your production order can be printed as a PDF file to bring it to the shop floor.

What Makes Our Service Special

Product Features

  • Work collaboratively in the cloud.
    Co-workers can view and clone production orders and cutting plans of the team. All data can be exported to Excel for the case of resigning from this service.
  • Allow flexibility in customer demand.
    The customer is not always strict with ordering roll quantities. Some customers allow overproduction which gives you opportunities to improve material utilization. CHAMPCUT takes advantage of such flexibility for your benefit.
  • Constrain your cutting plans by the maximum number of cuts.
    Note that the number of cuts is one less the number of knives of the slitting unit. The edges are counted as waste.
  • Constrain your cutting plans further by the maximum number of different widths per cutting pattern.
    Usually, customers allow only single width cuts to be packed on each pallet. If too many different widths are present in one cutting pattern, the workers doing the packaging have to deal with too many paletts at the end of the line making the operation difficult to handle. Other reasons might be limiting the complexity for manual labeling or restrictions of a packaging machine.
  • Constrain your cutting plans further by the maximum number of cutting patterns.
    For every cutting patterns the position of knives at the slitting unit is to be adjusted. This causes downtime for an offline slitting processes and waste production for an online slitting processes. The solver will find the best number of patterns by compromising the waste during knife positioning against the trime waste. However, you can also pass a hard constraint for the maximum number of patterns to the solver.
  • Minimize the total number of knife positionings.
    If your slitting unit is not capable of automatic knife positioning, then every individual knife change cost downtime or waste. By changing the sequence of patterns and the order of cuts within a pattern, CHAMPCUT can minimize the number of knife positionings.
See Examples Below

Portfolio

Some Real World Examples

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