How LINEALMATE™ Works

LINEALMATE's Schedule Maintenance allows you to prepare or modify production schedules.  A schedule is simply a list of orders you need to produce, listed in the order they are to be processed through production.  It allows you to create schedules directly in LINEALMATE™ or enter them from your business system and then bridge them into LINEALMATE™.   Schedule Maintenance may then be used to edit schedules before they are processed.  You may add, delete, or change order information, or review orders for accuracy.

Once schedules have been prepared, either in LINEALMATE™ or transferred from your business system, and modified, if necessary, you are ready to optimize.  LINEALMATE™ optimizes the schedules automatically, with no operator intervention.  The system displays the progress by indicating the layout it is currently processing; listing the inventory used and yield.  

LINEALMATE's Optimization Reports

LINEALMATE's wide range of reports improve scheduling and control of production and inventory by providing insight into such things as current inventory levels, optimization results and cutting/welding instructions.  Reports and easy-to read layouts are available in both hard copy and on-screen formats. 

LINEALMATE™ offers the following reports as part of the optimization process.

The Parameter Report lists those parameters that were considered when generating the optimized layouts.  So default parameters can easily be identified, an asterisk (*) at the end of a parameter description line indicates that the value being used is the default established when LINEALMATE™ was installed.  Items without an asterisk indicate changes made for this particular saw.

If the optimized results include scrap pieces that meet or exceed the minimum size requirements specified by Output Parameters 1,  then an Offal Report is produced, listing the size and quantity of offal produced and the layout in which they can be found. 

The Order/Layout Cross-Reference Report displays order numbers, quantity required, piece length, and bin location.  The +/- column reports any surplus or shortage in production.  The Layouts column shows the layouts in which a particular order-item is produced.

The report then lists summary information of total linear footage and number of pieces produced.

The Inventory Usage and Yield Summary contains inventory information for the schedule.  The columns under "Stock" reflect the usage of the inventory.  The Stock Used column shows how many stock pieces of a particular inventory were actually needed to produce an optimization solution.  The Stock Cut Column contains the linear footage of stock used (linear footage of the stock times the number of pieces used).

The columns under "Feet" reflect the amount of stock going to finished goods and reusable stock.  The Feet Fin (Finished) column contains the linear footage of the order-items produced.  The Offal column is the linear footage of the offal pieces produced from the cutting of each particular inventory.

The Loss column is the linear footage of stock, per inventory element, that could not be re-used such as trims or pieces too small to be classified as offal.

The report also lists total and yield information.

Cutting Layouts improve the handling and loading of stock by sorting by inventory stock size.  To increase saw positioner efficiency, the pieces within each layout are sorted by their size (Long to Short or Short to Long).  The report header shows the layout number, how many stock lengths are to be gang cut to fulfill this layout requirement, and layout yield. 

The Bin Report documents the bin assignments of every lineal piece.  LINEALMATE™ users have total control over the sequence in which their lineal material is sorted into bins.  The contents of the bins leaving the "saw area" correspond exactly to the sequence that unit requirements are passed, by the user, from their business computer into LINEALMATE™.  The unit's cut length, order identification, and part description are provided in the report.

The Usage Summary Report provides useful summary information on inventory usage by size of stock per run, selected by date range.  This report allows you to analyze yields to determine the best stock sizes for your operation; those producing the best yields.

LINEALMATE's Window Breakdown

LINEALMATE's Window Breakdown module allows for the entry and maintenance of all information related to the window formulas necessary for Bill-Of-Materials parts explosion. If your business system is unable to supply LINEALMATE™ with information already in the form of part numbers, the Window Breakdown module is used to breakdown each finished unit into all of its linear components (header, jam, rail, sill, etc.).  Your business system provides the window size and style and Window Breakdown calculates the necessary parts, quantities, and cut lengths.   

LINEALMATE™ Utilities

LINEALMATE™ is parameter driven, allowing you to significantly customize the system to meet your plant's operational needs, including the configuration of your carts and saws.

Maintenance utilities within LINEALMATE™ allow you to maintain data regarding your inventory and handle file maintenance. 

Optional LINEALMATE™ Modules

LINEALMATE™ provides an optional Cut Piece Label utility, printing labels to be placed on pieces after being cut.  Information includes bin location, order-item number, cut size and additional notes/remarks.

We see the following business benefits as a direct outcome from implementing PMC's products and services.

Optimal Yields

By taking advantage of computerized optimization, you experience increased efficiency of each sawing center by using less stock.  For all styles of windows you manufacture, you minimize cutting waste, conserve manpower and tighten control over production and inventory.  Optimization also analyzes the impact of cutting from different stock lengths and considers leftover "tail" pieces from previous runs to further increase yields.

Faster Optimization

You have the flexibility to create production schedules of the volume and in the sequence best suited to your operations.  Schedules can contain any mix of window styles and colors in the order you choose.  To expedite optimization, sets of schedules can be optimized for different workstations simultaneously.

A wide range of reports, available in both printed and on-screen formats, improve scheduling and control of production and inventory.

Seamless Integration

A powerful, formula-based window breakdown ability computes cut length requirements based on up to six different window dimensions, as required for oriel windows. Unique conditional formulas make it possible to maintain a single breakdown yet accurately define a wide range of different configurations and options, and the process can be expanded to handle glass requirements as well. 

In addition to interfacing with a wide range of automatic saws, the system also interfaces with linear positioners, machining centers, and automated welders for full plant efficiency and even more outstanding benefits.  PMC's excellent working relationship with equipment suppliers ensures seamless integration for your facility.

Easy implementation and use

During optimization, the system assigns bin locations to each piece, based upon the sorting methods already in use at your sawing centers.  As a piece is cut, the saw operator simply inserts the part into its bin.  Once all cutting is complete, the carts contain all the necessary window components needed to reach the assembly area in the sequence of your existing carts.

A variety of formats allow you to transfer cutting requirements from your existing order entry system.  This "Bridge" eliminates the re-keying of cutting requirements and the possibility of typing errors that can occur with manual data entry.