Introduction to Nested-Based manufacturing

In a nutshell, Nested-Based Manufacturing (NBM) is a concept where multiple components are cut out of a single sheet of material on a CNC router. All drilling, grooving and other machining occurs on the router as well. The NBM concept permits one operator to load raw material and unload finished parts. During machining time, the operator typically has time to perform other related functions such as edgebanding machined parts. Typical production yields 35 sheets of cut parts per 8-hour shift. With material handling tables, this number rises to 60 sheets per 8-hour shift.

Parts Hold-Down

Parts hold-down is achieved with a full-flow vacuum table and high capacity vacuum pump. Machining strategies in software take optimum advantage of the vacuum so that parts are kept in place through the processing of the entire panel.

Construction types

This type of machining is well suited to rabbet/dado construction and some types of RTA construction. Dowel construction can be achieved, but involves an off-line horizontal drilling (or drilling/doweling) machine. Some routers are equipped with horizontal drilling capability, but horizontal drilling of single components on the CNC router degrades overall performance; this is best done off-line.

Tooling discipline

Tooling discipline is very important with NBM. Product quality now depends on the quality of tooling used and monitoring tool wear. Tooling manufacturers are stepping up to the plate to provide high-quality, long-lasting tools that maximize product quality.

Parts shapes

Mixing rectangular and irregular shaped parts is where NBM excels. Also, just-in-time manufacture or made-to-order shops will benefit greatly from a machine that requires little setup and can produce a variety of parts from a single sheet of material.

Additional equipment

Traditionally, with Nested-Based Manufacturing, it is imperative to have a small panel saw in place to assist with cutting panels. This raises the level of efficiency in the shop to insure that the manufacturing process is not at a standstill while the router is producing finished parts.

Go with the flow

Cell-based and nested-based appear to be on opposite ends of the same pole. While it is true some shops are clearly on opposite ends of the pole, for more shops it's not so clear-cut.

Many shops that foresee the need to be positioned for medium volume manufacturing with a high degree of customization will adopt a mixture of NBM and cell-based technologies. Shops will soon see the benefits of combining efficient construction methods with elements that result in truly unique products -- custom products at high production pricing. In an age where global competition is stiffening, this kind of flexibility will become critical.

Considerations

Stiles Shop Solutions can tailor a system that helps you achieve a production flow to meet your needs today and position you for the future. In the meantime, here are some things to consider in your decision making process:

• Business Do you have a good handle on operating costs? Do you know your manufacturing costs? Where are you spending the most money today? Do you have a sales team, or are you the only salesman? Are you able to generate sufficient sales to keep a consistent flow of business?
• Product What is your finished product today? How will your finished product look tomorrow? What distinguishes your product from that of your competitors?
• Manufacturing Space How big is your manufacturing space today? How is it divided?
• Labor Force How many people touch the parts that comprise your products? What is their skill level? What is the employment picture in your region now? What steps are being taken locally to change that picture?
• Manufacturing Flow How do your parts move through your shop? What construction methods do you use today? Are these methods optimal and worth preserving? Do you foresee a change?
• Computers and Software What is your current level of computer literacy? What steps are you taking to beef up your computer skills? How about the skills of the people in your shop? What local resources are at your disposal to change this picture (e. g. community colleges, trade organizations, etc.)?

When you have considered these questions, please call your Stiles Shop Solutions representative, and we will assist you in determining which manufacturing solution, or combination of solutions, will suit your shop.

Products that support Nested-Based manufacturing:

Altendorf Sliding Table Saws