Paper waste ! Do you have the optimal paper widths ?

When a system performs calculations to find matching orders to run together in a greater width, it's possible if exist orders with compatible paper combination, if they are in a delivery range date, if they are a similar quantity, if they have a similar length,…, if…, if…, if... Once compatible orders run together, the paper width is a different one than those of these orders, but what are the possibilities this event occurs again ? and again ?, and again ? and so on until the end of life of these items. If all items may run in different widths, the tendency of width consumption depends on random events, right ?

Advantages Increase the possibility to run bigger widths. Reduce trim waste. Increase productivity. Etc. Disadvantages It’s so difficult to provide traceability to the purchase of paper per item, as well as the waste's sources. It is difficult to implement strategies to reduce width and level of paper inventory. The variation of consumption per width is unstable. In case of a sharp and prolonged lack of paper do not have a reliable basis for determining the purchase of paper widths. Etc.

But what happened if instead of letting the system look for the paper width combination an expert analyze the best alternative, specially for those with greatest impact on cost or productivity. Divide and conquer! Divide and conquer! The design team should analyze the ideal structure for every item besides to meet the customer requirements, the structure must ensure the lowest cost and higher productivity performance. This is the ideal stage where an item width must be analyzed.

This chart shows another perspective about the item’s widths. As you can see the smaller widths are easily combinable by itself to reach the greatest widths. Only widths between 130 and 149 cm facilitate the combination between different items. And between 150 and 200 cm are not easy to combine.

How does it look your consumption chart ? What are your most important widths ? Which widths will generate more waste ? Do you need to change your widths ?

So, do not worry about the small widths, the smaller the width, a greater possibility of combination may occur. But, why wait for the system to tell you the production’s day with which other items can be combined ? if you can combine it by itself since the design stage.

The items between 130 and 149 cm have two disadvantages: they may run in a small width and they may generate excessive trim waste. You may choose between find a match order to run together in the design stage (very recommendable) or let the system to perform a search the production’s day. This example shows you an opportunity of negotiation with other customers to select another item to combine, you may offer a discount in exchange a flexibility in the delivery date (only for those items whom worth it).

Advantages Increase the possibility to run bigger widths. Reduce trim waste. Increase productivity. It’s easy to provide traceability to the purchase of paper per item, as well as the waste's sources. It is easy to implement strategies to reduce width and level of paper inventory. The variation of consumption per width is stable. In case of a sharp and prolonged lack of paper you have a reliable basis for determining the purchase of paper widths. Disadvantages It need to assign one person to analyze the whole information about paper control everyday. It requires to adapt your information system to obtain the necessary information or create it.