Roll Size Optimisation in Action

In our example initially the Roll Size Optimisation is run with the eight roll sizes used in actual planning on a 2500 mm corrugator. The result shows 2,93% trim and an average roll size of 2203 mm.

This first result is usually better than the actual figures for the period and orders given because the simplified planning process differs slightly from actual planning under the restrictions and pressure of day-to-day business. However, it accurately reflects how the given orders fit on the given roll sizes. Improvements found using different roll sizes in subsequent runs are very likely to occur with the same magnitude in real-life planning, too.

The second run is done using two additional given roll sizes on a large 2800 mm corrugator.

The trim has improved by 0,4% to 2,54 %, the average width has increased to 2483 mm.

In the third run, the program was asked to propose the eight ideal roll sizes on the 2800 mm corrugator. With the same number of sizes as today, the new machine would yield 2,50% trim, and the average roll size would improve to 2519 mm.

Now the uncommon "ideal" sizes are replaced by more normal neighboring widths. The result has just a little more trim but is still much more efficient than the original roll sizes: The total trim is 2,57 %, the average roll size is down a little to 2514 mm.