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Calculating wire length yield

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    Calculating wire length yield

    I work in an industry where we install wire (fire, security, etc), and one of the biggest challenges is to get the best yield of wire off a spool. We generaly buy rolls of wire that are 1000ft. If I need 7,500 feet of wire for a job and order 8,000ft of wire, I can still run out of wire if the lengths are not taken into account. For example, there may be 600ft left total on 8 rolls, but the longest length on any given roll is only 200ft, but yet I need 250ft for my last wire. Now I either have to splice wire (not recommended or acceptable in most cases) or buy another roll.

    I currently have this job that has 52 different wire lengths, from 8ft to 386ft.

    So my challenge is to create an excel spreadsheet that allows me to enter in the amount of rolls of wire, and how much wire is on each roll. Then enter in all the different lengths of wire required, and have it calculate which rolls to cut off how much so maximize my yield, so that each roll is left with the shortest amount possible, then the last roll with the majority of wire that should have been left over in a single length. So basically if I have 8 rolls of 1000ft of wire, and I only need 7,500ft, then the last roll should have 500ft left on it and the other rolls empty (in a perfect world).

    Is this possible in Excel?

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    Re: Calculating wire length yield

    Welcome to the forum.

    Post a workbook with an example of the source data.
    Last edited by shg; 09-02-2010 at 05:23 PM.
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    Re: Calculating wire length yield

    This is commonly known as the cutting stock problem.
    http://en.wikipedia.org/wiki/Cutting_stock_problem

    Maybe somebody has an Excel program for it.
    Gordon in Rovereto, Italy

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    Re: Calculating wire length yield

    I don't have an example of the data other than the 52 different lengths of wire. I am stumpted to even know where to begin, and I am not a novice to Excel, but my math skills are lacking.

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    Re: Calculating wire length yield

    Maybe somebody has an Excel program for it.
    There are several; http://cutlistplus.com/fdefs.aspx is a 2D version, and Frontline Systems (the maker of Solver) offers a free workbook that includes a CutStock tab with an example (http://www.solver.com/procenter.htm) and pre-configured Solver model.

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    Re: Calculating wire length yield

    I've made a small Solver model for calculating wire length yield. This will not solve your problem but hopefully you will get an idea what you can do with solver.

    To guide solver I've added a cost column. Taking wire from a big roll costs more than if you take it from a small roll and leaving wire on a roll costs more if it's a small roll.

    All this to ensure that solver solves this problem as cheaply as possible by taking maximun amount of wire from the smallest rolls first.
    Attached Files Attached Files

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    Re: Calculating wire length yield

    Another approach, see attachment.
    Note that in the example, i enter 26 wire lenghts (half of your 52) and 500 ft rolls (half of your 1000 ft). Going for 52 lenghts and 1000 ft rolls seems to increase the possible combinations to the point where calculation takes forever.
    Attached Files Attached Files

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