MATERIAL CUT STANDARDIZATION

raw material optimization

SERVICE AREA:

IMEG was engaged by a leading manufacturer of finishing products to improve material efficiency and reduce production waste. The focus of this initiative was to standardize raw material cut sizes across multiple product lines and work centers to improve throughput, lower inventory costs, and reduce raw material scrap.

THE PROBLEM

Raw materials were cut in custom sizes that exceeded actual usage requirements
Significant scrap and unusable material were left over after each production run
An estimated 33% of all purchased raw material was being scrapped
Jumbo sheets of raw material arrived in inconsistent widths
Inconsistent cut sizes caused challenges across multiple work centers with varying machine tolerances
A wide range of finished goods required unique cut sizes, further complicating material flow and storage

raw material optimization

THE PLAN

IMEG developed a comprehensive capacity and material flow plan that included:

Assessed demand and usage for each type of raw material
Mapped material flow from raw input to finished goods through all applicable machines
Identified standard raw material widths to support the majority of product needs
Assigned optimal cut sizes to work centers based on tolerance and demand
Analyzed inventory cost implications and opportunities for scrap reduction
Designed storage plans and handling solutions for new standardized cuts, including mock-up carts and supermarket locations

scrap reduction strategies

THE RESULTS

The project resulted in significant gains in efficiency and material savings:

Standardized jumbo rolls to 54" wide, covering 60% of raw material usage
Standardized cut material widths to 18", enabling better divisibility and flexibility for smaller finished goods
Streamlined cutting processes for high-demand, uniquely sized products
Reduced raw material scrap to just 3.15%
Developed a new supermarket racking system for efficient storage of cut rolls
Created a u-cart system for ergonomic handling of the new raw material format
Delivered an actionable plan to roll out standardized material usage facility wide