Trimloss last updated

17th December 2016

by Julie Moorcroft

Moorcroft Computer Services

Thinking clear       Thinking software

Thinking Trimloss

 

by Julie Moorcroft

Moorcroft Computer Services

 

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Co-Ordinated Unit Assembly

 

 

Many factors are taken into account when deciding the racking sequence for glass, spacer bars and final unit labels.  All three of these elements eventually match automatically in the Trimloss production sequence without any operators having to do any searching or physical sorting at any point in the whole process.  This is why, when using the correct racking, Trimloss achieves the lowest labour costs with the quickest batch throughput times and the minimum of work in progress shop floor space, for a given batch size.  Even lead and Georgian units have their intermediate sequence calculated, avoiding any searching or sorting.  


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The design philosophy of Trimloss, is that unlike many competitor’s products, it should be able to process any mixture of glass types, or spacer bar types in any batch of work, without imposing any burdens on either administration, or shop floor operatives.  This often means that instead of having to fragment batch sizes to limit the variety of work attempted in each batch,  Trimloss can cope with taking on even bigger batch sizes, often yielding even lower glass optimisation waste and labour costs.  To achieve all these benefits, the final racking sequence for the whole batch is calculated before any glass type, or spacer bar cutting, bending, or optimising instructions are produced.  Even glass which is deemed for hand cutting has instructions to fit in with this totally co-ordinated production sequence.    There is therefore only one print run of the final unit labels in this co-ordinated sequence.  Even unit manufacturers making high quantities of each order item, benefit from this preplanned production sequence because location information printed on spacer bars can be unique even when the spacer bar sizes are not.  

This preplanned production sequence for any one batch of orders, firstly has all the results for units containing only annealed glass, followed by all the units containing any toughened glass.  This is to allow unit assembly on the annealed only units to begin straight after glass cutting, without having to wait for all the toughening to be completed.  Within each of these two categories, the next most important factor for the sort sequence is to separate ordinary units, Georgian units and leaded/artwork units.  The work for each of these categories needs to be racked separately, so that the Georgian and leading sections of the shop floor, receive only their relevant work.  

The final factors taken into account when calculating the preplanned production sequence, are the spacer bar thickness, material and colour.  This is essential for spacer benders which need operator intervention on a change of any of these factors and also makes for quicker operation on spacer benders which can automatically handle any sequence of spacer bars.  Even when the Trimloss spacer bar optimisation is used, the racking sequence still matches the same preplanned production sequence.  

There is a different preplanned sequence for single glazed work, whether it be annealed, or toughened.  In this case, the major sequence is the delivery date, followed by the delivery route, then the customer identification.  Trimloss is told the maximum height for racking on the delivery vehicle.  Any glass pieces whose large dimension is larger than this height need to be transported lying on their side, so they are then sorted into a descending sequence of their small dimensions.  Any glass pieces whose large dimension is smaller than this maximum vehicle racking height, can be transported standing vertically, so they are then sorted into a descending sequence of their large dimensions.  These features make vehicle loading much easier and quicker.  For toughened glass processors, the preplanned sequence applies after the glass is toughened with optional laser applied racking instructions in the 10mm border of the glass.  Prior to toughening, the glass is sequenced initially into the correct sequence for the Trimloss optimised toughened bed loading.  For unit manufacturers who buy in their toughened glass, there is a feature to cause the preplanned sequence information to be printed on the suppliers glass label, enabling the same co-ordinated production as annealed units.  

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The variety of solid spacer bar thicknesses, materials and colours that a unit manufacturer might be asked to make can now number about 200 or more.  The capabilities of different spacer bending machines also vary widely, the most advanced being able to adjust automatically to successive spacer bars of different thicknesses and the least capable needing a 5 minute manual change of the bending head.  

 

There are also considerable differences in the time to switch from one spacer bar thickness, material or colour to another.  The most advanced machine can do this completely automatically, whereas the least capable requires much manual intervention.  

 

There are also considerable differences in the time taken to bend each spacer bar, the fastest bender operating at about twice the speed of the slowest.  

 

Older spacer benders cannot bend the latest solid warm edge spacer bar materials without considerable modification.  You have been warned.  

 

Whatever the make of bender, the operation from Trimloss generated instructions is going to be easier and quicker.  There is a bender which tries to minimise timing overheads, by including a data sort feature in its operating console.  Whereas this will speed up the production of spacer bars for inferior optimisers, it will do nothing to achieve a co-ordinated sequence of either glass or final unit labels, leaving the operators to carry out much sorting of one component or another.  With Trimloss however, this sort process is completely redundant.  

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We do not believe there is any glass optimiser in the whole world with anything like the host of very beneficial features described here to improve profitability.  

In the leading and Georgian departments, the operators need to work on all the units for each window in turn, so that they can get the leading and the Georgian grills to line up correctly.  For this reason, there are extra lead and Georgian reports which are in window sequence, but with references back to the original preplanned production sequence, to find the glass or spacer bars on which to work.  After the work has been done, the glass and spacer bars are then slotted back into their original preplanned production sequence, so that glass, spacer bars and final unit labels still match up perfectly as with all other units.