Cutting and stock

Profile arrives in stock bars, and it is parts that go into a product. Cutting answers how many stock bars to buy, how to lay the parts out on them and what to do with the remainder.

An order is cut as a whole, not product by product#

Every product is calculated on its own — as if stock bars were bought for it alone. But there is one saw, and the order goes to it as a whole. So the system reassembles the order: parts of one article number and one colour from all calculated items are merged into a common pool and laid out on the stock bars together. An offcut from a door is topped up with a window part, and fewer stock bars are used. Different colours never share a stock bar — those are physically different stock bars.

The difference goes straight into the item prices of the order: the materials of every product are priced from its share of the common purchase. There is no separate «discount» row any more — the item prices add up to the total, and the order costs what we will actually pay the supplier. About prices — on the Orders page.

Stock bars: three different numbers#

The standard length belongs to the material. Справочники → Материалы, the «Длина хлыста, мм» field. For profile, reinforcement and glazing bead it is mandatory, and their unit of measure is «м.п.».

The one-off length belongs to the order. The order card → «Нестандартные длины», the «Длины хлыста в заказе» window. An arrangement with the factory for a single order: "we will bring stock bars of this length". The price per metre stays the same, but for every non-standard stock bar the factory charges a surcharge, and it enters the calculation. Change only those rows where the factory brings something different. If a part of the order does not fit into the given length, the system will name it and list the available lengths. On a closed order the lengths do not change.

What the factory is willing to cut belongs to the profile system. Справочники → Профильные системы, the «Надбавка за хлыст» and «Длины, которые режет завод» columns. The factory cuts from a minimum to a maximum with a given step; the fields are «Минимум, мм», «Максимум, мм», «Шаг, мм».

The stock group: one profile in several lengths#

Sometimes the factory brings one profile in two lengths — a six-metre and a three-metre false mullion, for example. In the catalogue those are two rows with their own prices, but for cutting they are interchangeable and are united into a stock group.

Cutting mixes lengths only within a group — and it does so at the level of the whole order: it picks how many stock bars of each length will come out cheaper. A single product is always calculated with one length. The group is set up when the catalogue is loaded.

Kerf width#

Настройки → Производственные параметры, the «Ширина реза (пила), мм (1–20)» field, 3 mm by default. This is the metal the saw eats up on every cut; in the "Материал и остатки" block it is shown as the «Пропил» row.

The number is small, but it decides whether one more part fits into a stock bar. Two parts of 3122 mm fit into a stock bar of 6300 mm as long as the kerf width is no more than 28 mm — and stop fitting as soon as it is larger: not a single part has changed, yet twice as many stock bars are needed. Set it by your own saw, not "roughly".

The cutting plan#

The order card → «⋯ Ещё» → «Раскрой»; the same menu downloads the PDF — «Карта раскроя».

This is a document for the shop floor: one job for the whole order. In the header — the number of stock bars and the average efficiency, then the legend: деталь, в дело, в лом. Further on, for each group (article number + colour + stock bar length) there is a table with the columns «Схема», «Хлыстов», «Резы, мм», «Раскладка», «Хвост», and in its header — how many stock bars and patterns, the efficiency, the number of cuts, how many tails go to use and how many millimetres go to waste.

Identical stock bars are collapsed into one pattern with a multiplier: a hundred identically cut stock bars are printed as a single row. For the same reason stock bars are not numbered.

The hint about a profitable stock bar length#

The system does not change the order by itself — it shows a hint, and the decision is yours.

The sign on the order card. When the cutting looks bad, «Раскрой можно улучшить» appears with figures of the kind "N хлыстов · отход N %"; otherwise — «Раскрой в норме», and the system can be asked in that case too. The thresholds are in Настройки → «Подсказка длины хлыста»: no fewer than N stock bars in the order (15 by default) and waste above N % (30 by default). Both conditions work together.

The selection itself is the «Подобрать длину хлыста» button, the «Возможные длины хлыста» window. The system goes through the lengths in the factory's grid and for each one calculates: how many stock bars will come out instead of the present ones, what the waste and the purchase will become, how much the factory will take as a surcharge. The surcharge is already deducted — the bottom line is shown, not the gross saving.

• Nothing is saved: the calculation is made on the current prices and the current composition of the order and goes stale together with them. Only the accepted length lives long.
• «Заказать этой длиной» adds the length to the current ones, it does not replace them.
• Agreeing it with the factory is on you, and the window warns about that in the confirmation.
• If it was not calculated for the whole order, you will be told so — for which systems there was nothing to calculate with and which rows dropped out.

If the system's length limits are not set, the hint answers «Не знаем, какие длины режет завод».

Offcuts: the usable remnant and the waste#

The tail of a stock bar is split in two by a single number — the minimum usable remnant (300 mm by default). A tail no shorter than that goes в дело, a shorter one goes в лом.

The totals are in the «Материал и остатки» block of the order card: «Закуплено», «Использовано», «Пропил», «Деловой остаток», «Отход», «Утилизация» and a table by article number. The cost price of the remnant and of the waste is visible only to the owner and the sales manager.

As long as remnant accounting is switched off, the usable remnant stays a figure in a report: it does not reach the stock.

Stock#

The «Склад» section. Accounting is switched off by default — the owner turns it on with the «Учитывать остатки на складе» checkbox in the «Настройки склада» block; the «Минимальный деловой остаток, мм» is set there as well. The tabs are «Остатки материалов» and «Деловые обрезки», plus the «Журнал движений».

What the stock does today:

• Keeps balances by the "material + colour" pair: «+ Приход материала», a correction is «Корректировка» with a mandatory reason.
• Keeps usable offcuts — by hand with the «+ Приход обрезка» button, or automatically after the cutting of orders handed to production.
• Writes off on handover to production: suitable offcuts first, then whole stock bars, and usable tails are taken back into stock — by the same common cutting that is printed in the plan.
• Substitutes offcuts into the cutting instead of a whole stock bar, as long as accounting is on.
• Remembers every movement: «Ручной приход», «Корректировка», «Списание в заказ», «Оприходование обрезка», «Расход обрезка».
• Does not block production. If an offcut was short, the order will go into work with the warning «Часть материалов списана без остатков склада», and the cost price does not change.

What the stock cannot do — so that you do not go looking:

• Accounting covers only materials that get cut — profile, reinforcement, glazing bead. Insulating glass units and hardware do not reach it: those are separate catalogues.
• There is not more than one stock: the balance is single for the company, there is no breakdown by premises or areas.
• There is no reservation for an order — material is written off at the moment of handover to production.
• There is no minimum stock level and no shortage notifications.
• Receipts from a supplier are not entered by themselves: you record a purchase by hand.
• A balance row cannot be deleted — only corrected with a reason given.

Who is allowed to change what#

The surveyor has no access to the stock and the remnants.