Advanced Material Yielding Software Could Change the Plastics Industry
The American manufacturing industry has seen major
strides in the field of process improvement software &
technology over the past several years. These technological
and software advances are also available to the plastics
industry, yet the vast majority of distributors and fabricators
are not utilizing technology improvements to their
As technology advances, we now find ourselves experiencing
a fourth industrial revolution, which is becoming
known as “Industry 4.0.” While the plastics distribution
and fabrication industry may not be considered a prime
market for complex automation and innovative web based
software, you might be surprised to learn that cut-to-size
yield optimization technology has experienced substantial
strides in its ability to efficiently reduce material scrap,
which results in generating more sales and profit.
Historically, The Itemizer has been the most popular
optimizer used by the plastics distribution industry.
However, a new company, Falcon Optimizer LLC has
recently been launched with the aim of changing the way
material-yielding software is used in the plastics industry.
Falcon Optimizer’s web based software significantly
improves substrate yield by an average of 10% and has
never been beaten by any other optimization software.
It is now more important than ever to utilize today’s
technology for dramatically improving material yield optimization. The plastics industry must focus on ways to
improve margins, reduce material waste and find new
ways to generate higher profits. Cut-to-size yield optimization
software offers a powerful tool to achieve these objectives and far too many plastics distributors and fabricators
continue to lag behind today’s yield optimization
technology. Embracing change can be slow and difficult
but not changing can be devastating to the bottom line.
The industry needs to understand that yield optimization
is achieved through complex algorithms, and
not by a simple mathematical equation or formula.
Yielding is not straightforward and instead must use
concepts and theories until a good solution is found.
Incorrect yield calculations result in cutting more material
than necessary to produce the same number of
parts. These theories must be condensed into a programming
language to be run with the actual cutting
data (part sizes, sheet sizes, saw blade kerf, etc.) to
determine the best result. Here-in lies the major difference
between yesterday’s calculations and today’s
advanced algorithm technology.
Here are two “simple” optimizations that highlight the
major differences in optimization technology. The example
consists of yielding the most number of (5.00” x 9.00”)
parts from one sheet size (48” x 96”) using a .125” saw
Imagine if the customer requires a “moderate”
optimization that consists of 3 or 4 different
part sizes cut from 2 or 3 different
sheets sizes. Or better yet, imagine the customer
requiring a more “complex” optimization
that consists of 25, 50 or even more part
sizes cut from 5 or 10 different sheet size
It is this specific area that has seen tremendous
gains over the past two decades. Today’s
computer systems have the ability to run more
pattern combinations, and can test a greater
combination of results. At the end of the day, the quality
of the software code built into the yield optimization software
can literally mean the difference in many millions of
dollars in lost profit. Based on what the average plastics
distributor is doing today, the wrong optimizer could be as
costly as throwing money down the drain!
Falcon Optimizer is on the cutting edge of material yield
optimization software. Developed uniquely for the plastics
industry, this new optimizer technology gives users unparalleled
yields. This new optimizer technology also offers
built in individual part pricing calculations, the ability to
quickly and easily import pattern files directly to a wide
variety of CNC panel saws, as well as web based access
which removes the need for downloading or installation of
any files. Falcon Optimizer is also in development of additional
features such as labor rate calculations, length of
cutting times, labor pricing per part, and more.
For more information, Aaron Rappaport, Managing Director, Falcon Optimizer LLC. For more information or to schedule a demonstration on improving your cut-to-size yield optimizations, contact Aaron Rappaport (x118) or Michael Batky (x115) at Falcon Optimizer, 4440 PGA Blvd., Suite 505, Palm Beach Gardens, FL, 33410, 800-583-4726, E-mail: firstname.lastname@example.org, Web: www.falconoptimizer.com.