Nested-Based Manufacturing:
Material Optimization through Machine and Programming Software Integration

In a Level I Nested-Based work cell a CNC router is driven by programs that contain nests of components that are generated by a CAD/CAM system such as AutoCAD and Router-CIM. Automated nesting software such as AutoNest is a great option for reducing the time it takes to develop nests of components. Higher-level work cells are essentially the same but utilize more extensive software to automate the design, nesting and machine code development.

In a Level II Nested-Based work cell product and component design is enhanced with a parametric extension for the CAD system. For AutoCAD users Mechanical DeskTop (MDT) will be used. Many cabinet shops and store fixture manufacturers will use cabinet design software as an automated solution for this level such as Cabinet Vision or CabNetWARE from Planit Systems.

In a Level III Nested-Based work cell the nesting and machine code generation is completely automated. This is accomplished with Second Shift software from CIM-Tech. For example, a Second Shift software package can be designed specifically for companies using certain cabinet design software that automatically extracts all *.dxf files needed for an entire job directly from that third-party cabinet software. It then creates the nests and generates all of the machine programs for the sheets of material to be machined. This could be done after-hours, unmanned - hence the name Second Shift. Many companies design products all day, load the designs into Second Shift, and return the next morning to have several days' worth of machine code developed and ready for the machining process.

In developing and justifying a Nested-Based work cell it is very important to consider the impact each level will have on your business. A properly equipped CNC router can machine a nest of parts in 5 to 8 minutes and it takes a designer/programmer set up with AutoCAD, Router-CIM and AutoNest 15 to 20 minutes to program a sheet nested with parts. It is also very important to focus on the production and programming requirements of your business and not the size of your business. For example, a large upholstered furniture manufacturer that produces a line of standard products in substantial quantities may never require more than a Level I Nested-Based work cell because they can afford the time to program and manually nest their work. If this same company needs to run high volume/low quantity (or JIT) they might require a Level II Nested-Based work cell. A small cabinet shop that produces all custom cabinets may require a Level III Nested-Based work cell.