Workshop

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Workshop

  1. 2. Cutting & Packing Workshop Spring 2008
  2. 3. Furniture Manufacturing
  3. 4. Upholstery Industry <ul><li>Manufacturing process </li></ul><ul><ul><li>Design </li></ul></ul><ul><ul><li>Wood frame cutting </li></ul></ul><ul><ul><li>Assembly </li></ul></ul><ul><ul><li>Foam </li></ul></ul><ul><ul><li>Textile cover </li></ul></ul><ul><li>Production technology – cutting machines </li></ul>
  4. 5. Wooden Frame
  5. 6. Wooden Frame
  6. 8. Wood Cutting
  7. 9. Fabric Cutting
  8. 10. Foam Cutting <ul><li>Movie: http://www.youtube.com/watch?v=-CnUjwqKUDw </li></ul>
  9. 11. Assembly Assemble wood frame & springs Cochins and Textile cover
  10. 12. 2D Cutting <ul><li>Wood </li></ul><ul><li>Metal </li></ul><ul><li>Textile </li></ul><ul><li>Foam </li></ul>
  11. 13. CNC Router Heads Hold-down system Tables Tool changer Controller
  12. 14. <ul><li>Accu-Router Movie </li></ul>
  13. 15. Fabric Cutting
  14. 16. What does it have to do with computational geometry <ul><li>Given a set of 2D shapes (polygons): </li></ul><ul><ul><li>place the shapes on a material such that they will not intersect. </li></ul></ul><ul><ul><ul><li>Variant #1: Use infinite roll with a given width. </li></ul></ul></ul><ul><ul><ul><li>Variant #2: Use sheets of material with a given width and length. </li></ul></ul></ul><ul><ul><li>Optimize your solution to use as little material as possible. </li></ul></ul>
  15. 17. Business Value - Example <ul><li>Bassett Furniture ( http://www.bassettfurniture.com ) </li></ul><ul><ul><li>$300M in revenue per year </li></ul></ul><ul><ul><li>13 routers </li></ul></ul><ul><ul><li>Cuts ~650K sheets for ~650K frames. </li></ul></ul><ul><ul><li>$13M cost of wood </li></ul></ul><ul><ul><li>$26M cost of foam (outsourced) </li></ul></ul><ul><ul><li>$26M cost of fabric </li></ul></ul><ul><ul><li>Total $65M material </li></ul></ul><ul><li>  Saving 5% wood material = $650K per year </li></ul>
  16. 18. Different approaches to the nesting problem <ul><li>Manual nests (or semi automatic): </li></ul><ul><ul><li>Human made </li></ul></ul><ul><li>Automatic nests </li></ul><ul><ul><li>Software made </li></ul></ul><ul><li>Static nests </li></ul><ul><ul><li>Nest few kits and use the same nest again and again </li></ul></ul><ul><li>Dynamic nests </li></ul>
  17. 19. Dynamic approach <ul><li>Advantages: </li></ul><ul><ul><li>Nest according to demand. </li></ul></ul><ul><ul><li>Nest the exact amount of needed parts. </li></ul></ul><ul><ul><li>Support custom styles. </li></ul></ul><ul><ul><li>Mix different jobs of the same material. </li></ul></ul><ul><li>Disadvantages </li></ul><ul><ul><li>A lot of nesting work – requires software. </li></ul></ul><ul><ul><li>Each nest is different – sometimes cause difficulties in production process. </li></ul></ul>
  18. 20. Example – build you own furniture <ul><li>http://www.bassettfurniture.com/tools/custom-upholstery/custom-upholstery.asp?type=loft </li></ul>
  19. 21. Additional Options <ul><li>Keep grain direction: part cannot be rotated. </li></ul><ul><li>Stripes and plaids </li></ul>
  20. 22. Additional Options (cont.) <ul><li>Hold-down systems & cut order (wood) </li></ul><ul><ul><li>Vacuum </li></ul></ul><ul><ul><li>Rollers </li></ul></ul><ul><li>Flexible </li></ul><ul><li>Fires (cut path) </li></ul><ul><li> Movie: http://www.youtube.com/watch?v=-CnUjwqKUDw </li></ul><ul><li>Foam (cannot leave material during cut) </li></ul><ul><li>Stacking (foam) – Cut time/ efficiency trade-off </li></ul><ul><li>Leather – quality areas </li></ul>
  21. 23. Metal cutting – Laser Machines
  22. 24. Laser cutting <ul><li>Movie </li></ul><ul><li>Restrictions: </li></ul><ul><ul><li>Heating </li></ul></ul><ul><ul><li>Tabs – holding small parts </li></ul></ul><ul><ul><li>Small parts first </li></ul></ul>
  23. 25. Metal Cutting – Waterjet machines

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