Material Accountability in Multi-Job Order Production

Customer Introduction:

The client is a sheet metal fabrication company specialising in precision cutting using laser cutting machines. Large metal sheets are loaded into these machines, and parts are cut based on nesting plans. Each nesting yields components for multiple job orders, with leftover material categorised as either reusable sheet, scrap (Jali), or process loss.

Challenge

In this production setup, a single laser cutting operation simultaneously fulfils multiple job orders, with varying quantities and part weights depending on the nesting. This created a significant challenge:

• How to accurately track and account for how much of each sheet was converted into usable components?
• How much of the leftover sheet could be returned to inventory?
• How much scrap was generated?
• What portion was process loss?

apturing this data manually required multiple entries, leading to inefficiencies, errors, and lack of real-time visibility into material consumption and wastage.

The Solution:

To address this, OurSys introduced a dedicated enhancement to its Multiple Job Order Production module.

• A single-screen data capture interface to record all material outcomes from one production cycle.
• Automatic pre-filling of expected output quantities based on the Bill of Materials (BOM), with the flexibility for users to make adjustments based on actual output.
• Real-time calculation of unaccounted material (e.g., scrap, leftover, and process loss), ensuring full traceability.

The Result / Benefits:

• Complete material accountability without requiring multiple entries.
• Reduced manual effort and data entry errors.
• Improved visibility into process efficiency and material usage.
• Applicable to any manufacturing process where a single input is transformed into multiple outputs in one operation.

This enhancement has enabled the customer to streamline production tracking, reduce wastage, and improve inventory accuracy ? all from a single, integrated screen within OurSys ERP.