Automated Routing Generation
Blog Post 4.03.01 - Generate Optimal Shop Floor Routings
Utilize Routing Configurator to generate optimal shop floor routings. Read More ...
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Generate Optimal Shop Floor Routings
Global Edge Engineering Assistant includes the capability to automatically analyze sheet metal CAD part parameters including a built-in Configuration Engine. A combination of these two capabilities makes it possible to generate optimal routings based on cost and/or delivery time.
This includes an analysis of manufacturing process comparisons such as a turret punch versus a laser cutter, which compares fabrication time versus fabrication cost. Global Edge Engineering Assistant takes the guess work out of the routing generation process with features and benefits that include:
This includes an analysis of manufacturing process comparisons such as a turret punch versus a laser cutter, which compares fabrication time versus fabrication cost. Global Edge Engineering Assistant takes the guess work out of the routing generation process with features and benefits that include:
- Automated Analysis of Customer Specifications / CAD Drawings
- Automated Routing Generation from CAD Part Parameters
- Automated Material Size Selection for Sheet Metal Nestings
- Automatically Determines How Sheet Metal Parts are Fabricated
- Eliminates Manual Routing Generation of Sheet Metal Parts
- Determines Most Cost Effective Routing to Fabricate Sheet Metal Parts
Generating Optimal Shop Floor Routings with the Routing Configurator and Global Edge Engineering Assistant
Automating Efficiency in Sheet Metal Fabrication
In today's competitive manufacturing environment, efficiency and precision are paramount. Shop floors are increasingly complex, and the demand for faster turnaround times and lower costs continues to grow. To thrive, companies must leverage advanced technology to optimize every aspect of their production process. One of the most promising breakthroughs is the automation of shop floor routing decisions—particularly for sheet metal fabrication—using sophisticated tools like the Routing Configurator and the Global Edge Engineering Assistant. This powerful combination transforms how manufacturers approach routing, making the entire process more streamlined, data-driven, and cost-effective.
The Role of Shop Floor Routing in Manufacturing
At its core, shop floor routing is the process of determining the sequence of operations a part will follow as it moves through production. For sheet metal parts, this can involve multiple steps—cutting, punching, bending, welding, and more. Historically, routing has been a labor-intensive process, often reliant on the experience and intuition of engineers and planners. Manual routing is not only time-consuming but can also introduce inconsistencies and inefficiencies, resulting in higher costs and longer lead times.
Introducing the Routing Configurator and Global Edge Engineering Assistant
The evolution of digital manufacturing tools has enabled a new paradigm: automated routing generation. The Routing Configurator, paired with Global Edge Engineering Assistant, brings together advanced analysis, intelligent algorithms, and a powerful configuration engine. This duo empowers manufacturers to automatically analyze customer specifications and CAD part parameters, and then generate optimal shop floor routings based on cost, delivery time, or a combination of both.
Key Features and Benefits
- Automated Analysis of Customer Specifications and CAD Drawings: The system ingests CAD files and customer requirements, extracting relevant part parameters such as material type, thickness, geometry, and tolerance requirements. This analysis forms the foundation for accurate routing decisions.
- Automated Routing Generation: Leveraging the Configuration Engine, the assistant automatically determines the most effective sequence of fabrication steps based on the specifics of each part.
- Automated Material Size Selection for Nestings: The assistant assesses available material sizes and optimizes nesting layouts, minimizing waste and reducing costs.
- Automatic Determination of Fabrication Methods: By comparing the capabilities and efficiencies of available equipment—such as turret punches versus laser cutters—it selects the best process for each job.
- Elimination of Manual Routing Generation: Automated routing eliminates the guesswork, reduces errors, and ensures consistency across jobs and shifts.
- Cost-Effectiveness: The assistant identifies the routing with the lowest cost to fabricate each part, taking into account all relevant variables.
How Automated Routing Generation Works
The process begins with the submission of a sheet metal part in the form of a CAD drawing, accompanied by specific customer requirements. Global Edge Engineering Assistant automatically parses the drawing, extracting critical parameters such as:
- Material type and gauge
- Part geometry and size
- Tolerance and finish specifications
- Quantity and delivery requirements
With this data, the Configuration Engine evaluates all available routing options within the shop floor environment. It compares different fabrication processes—such as turret punching versus laser cutting—noting the trade-offs between cost and production time. For example, a laser cutter might offer faster cycle times for complex geometries, but at a higher operating cost, whereas a turret punch may be more cost-effective for high-volume runs with simpler shapes.
Global Edge Engineering Assistant then generates a routing that balances cost, lead time, and resource availability. The user can prioritize either parameter, or the system can recommend an optimal balance based on pre-set criteria. The result is a routing plan tailored to the specific needs of each order.
Comparative Analysis of Manufacturing Processes
A critical component of optimal routing is the comparative analysis of available manufacturing processes. The Routing Configurator weighs the strengths and limitations of different fabrication methods, factoring in variables such as:
- Cycle time per part
- Material utilization and waste
- Machine setup and changeover times
- Labor requirements
- Energy consumption and maintenance costs
For example, when deciding between a turret punch and a laser cutter, the assistant may consider:
- Turret Punch: Lower operating cost for standard features, especially at high volumes. May be slower for intricate designs or thick materials.
- Laser Cutter: Faster and more flexible for complex or custom geometries. Higher per-minute operating cost, but potentially lower total time for small batches or intricate parts.
By running detailed simulations and cost/time analyses, the configurator ensures that each part follows the most advantageous path through the shop floor.
Material Size Selection and Nesting Optimization
Material efficiency is another critical factor in reducing manufacturing costs. The Configuration Engine automatically selects the optimal sheet size for each job, based on part geometry and existing stock. It then calculates the most efficient nesting pattern to minimize scrap and maximize yield.
Automated nesting reduces not only material costs but also handling and setup time, further accelerating the production process and improving overall shop floor utilization.
Removing Guesswork from Routing Decisions
Traditionally, routing decisions have required significant judgment and experience. With Global Edge Engineering Assistant, manufacturers can move away from subjective decision-making. The system leverages large databases of machine capabilities, historical job parameters, and current shop floor conditions to recommend the best routing every time.
This data-driven approach reduces errors, improves repeatability, and allows even less experienced personnel to achieve optimal results. It also facilitates rapid scaling, as best practices are embedded in the configuration logic.
Business Impact and Value Proposition
By automating the generation of optimal shop floor routings, manufacturers realize significant benefits:
- Reduced Lead Times: Automated routing accelerates job setup, allowing more parts to move through production in less time.
- Lower Costs: Waste minimization, process optimization, and machine utilization improvement directly reduce the cost per part.
- Increased Consistency and Quality: Automated decision-making ensures that every part follows the best possible path, reducing variability and boosting product quality.
- Greater Flexibility: As new equipment or processes are added, the Configuration Engine adapts automatically, supporting continuous improvement initiatives.
- Enhanced Competitiveness: Faster quoting, improved delivery times, and lower costs enable manufacturers to win more business and grow market share.
Real-World Example: Sheet Metal Part Routing
Consider an order for a batch of complex sheet metal enclosures. The customer requires a tight delivery window and cost competitiveness. Using the Routing Configurator and Global Edge Engineering Assistant, the manufacturer imports the customer's CAD file. The assistant extracts material, geometry, and tolerance data, then simulates multiple routing scenarios.The Configuration Engine identifies that, for the given quantity and complexity, laser cutting is more time-effective, despite higher per-minute costs, and nesting optimization allows for material savings. The system generates a routing plan that schedules laser cutting for initial fabrication, followed by automated bending and spot welding, all sequenced for minimal material handling.Consequently, the manufacturer delivers the parts ahead of schedule and under budget, with full traceability and documentation of the process.
Future Directions and Integration
As manufacturing continues to digitize, the potential of automated routing solutions will only grow. Integration with ERP, MES, and IoT systems can further enhance the capability of the Configuration Engine, enabling real-time scheduling adjustments, predictive maintenance, and automated material replenishment.
Machine learning and AI-driven optimization will allow the system to learn from past production runs, continuously refining routing recommendations for even greater efficiency and cost savings.
Conclusion
The combination of the Routing Configurator and Global Edge Engineering Assistant represents a transformative leap forward for shop floor routing in sheet metal fabrication. Automated analysis of CAD drawings, intelligent process comparison, and optimization of material usage create a robust, repeatable framework for generating optimal routing plans based on cost, lead time, or both.
By embracing these advanced tools, manufacturers can unlock new levels of efficiency, consistency, and competitiveness—ensuring their operations are ready for the challenges of the modern industrial landscape.
Increase Shop Floor Velocity
To see a demonstration as to how Global Edge Engineering Assistant can increase your engineering capacity, click on the link below to schedule a software demonstration.