Primary focus
Cutting-Stock Optimization
Exploring more efficient cutting patterns for metal tubing, bar stock, aluminum extrusions, and other linear materials, accounting for stock lengths, saw kerf, reusable remnants, and multiple customer orders.
Better use of materials. Smarter production decisions.
Exploring practical optimization methods to help manufacturing shops reduce material waste, improve cutting plans, and simplify complex production decisions.
Share Your Experience240 in stock length
Where Optimization Meets the Shop Floor
Figure 1. The same 4 orders, cut two ways
15 parts from 4 customer orders, cut from 20 ft bars. Both patterns use the same stock and leave the same total offcut. What differs is the shape of what is left over.
Cut in the order received
3 bars. Scrap: 14.875, 12.125, 12.125 in. No offcut long enough to keep.
Planned as one set
3 bars. Scrap: 0.5, 2.125 in. Kept for reuse: 36.5 in.
Parts ordered
- A 68 in × 2
- B 52.5 in × 5
- C 39.75 in × 5
- D 27.25 in × 3
Stock
240 in (20 ft)
Saw kerf
0.125 in per cut
Offcuts
- Scrap, under 24 in
- Remnant kept, 24 in or longer
Conceptual illustration — not actual production results.
Secondary areas, at an exploratory stage
Material Waste & Remnant Reuse
Investigating how shops manage leftover material and whether practical optimization could improve material utilization beyond existing workflows.
Production Scheduling
Exploring how shops coordinate machine availability, setup times, urgent jobs, and delivery deadlines when planning becomes difficult.
Independent Research. Practical Problems.
Applied Ops Lab is an independent research initiative based in Morris County, New Jersey, exploring how mathematical optimization can address practical challenges in manufacturing operations.
The current focus is understanding how fabrication shops plan cutting jobs, manage material remnants, and handle production constraints—and where existing software still leaves room for manual work.
How Does Your Shop Handle Cutting Plans?
I’m currently speaking with fabrication professionals to understand how cutting plans and material utilization are managed in real-world operations.
Does your shop rely on dedicated cutting software, spreadsheets, or manual adjustments? I’d welcome a brief exchange about what works well and what remains difficult.
Send an Email
Or write directly to greg@appliedopslab.com