Case Study 

In 2003, we developed BatchBan dynamic optimization software. Until then, glass companies used a batch style optimization which resulted in diminishing yields as the runs progressed. An operator could begin with a 90% yield and end the batch with a 50% yield on the last sheet because they would run out of material.

 

To test out the new dynamic software,

we asked Cardinal Spring Green to try it and provide feedback. In their initial test phase, they found that the HP3 Software could save them significant money in glass usage.

 

In fact, they asked to purchase the software with exclusive rights, preventing HP3 from selling it to any Cardinal competitors. That exclusivity request was not granted, but Cardinal was permitted to purchase a copy of the source code, which they turned into their in-house software currently being used in all of their facilities.

 

Here is a sample of the data collected from Cardinal’s test of HP3 Software.

HP3 Cardinal Chart 1.png

Stock Size

Original

Batch Yield

______________

91.4%

93.1%                 

93.0%

92.2%                 

92.0%

____________

72" x 84"

84" x 110"      

96" x 130"

108" x 144"    

132' x 204"

BatchBan Optimized Yield

________________

92.3%

94.7%                     

95.2%

95.9%                     

96.9%

Change in Yield

__________

+0.9%

+1.6%        

+2.2%

+3.7%        

+4.9%

HP3 Cardinal Chart 2.png

Waste Cost Per Shift = (Clear Cost Per Sq. Ft. + LowE Cost Per Sq. Ft.) * Waste / Shifts Per Day

Annual Waste Cost = Waste Cost Per Shift * Shifts Per Day * Days of Week * Weeks Per Year

Annual Savings = Annual Waste Cost of Batch - Annual Waste Cost of BatchBan

Cardinal Glass Industries.jpg
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