Sheet Metal Scrap: Cut, Remnant and Rejection Log
Reconcile a sheet into accepted parts, reusable remnant, process scrap and rejected parts while preserving cut-plan revision, cause and location.
Sheet metal scrap control starts with a mass or area balance for each cut plan. Accepted parts, reusable remnants, process scrap and rejected parts need separate identities so a later improvement can be measured honestly.
A scrap bin total cannot show whether the loss came from nesting, trim, setup, handling or rejected parts. Link the material outcome to the sheet, cut plan and work order.
Reconcile one 100 kg sheet
| Outcome | Weight | Record needed |
|---|---|---|
| Accepted parts | 72 kg | Part, quantity and work order |
| Reusable remnant | 18 kg | Remnant ID, grade, heat, dimensions and rack |
| Process scrap | 7 kg | Cut-plan source and scrap category |
| Rejected parts | 3 kg | Defect, inspection and disposition |
| Total | 100 kg | 72 + 18 + 7 + 3 |
The process scrap rate for this sheet is 7%. Rejected-part material is shown separately at 3%. Combining them may be useful for a total material-loss view, but preserve both causes.
Use a cut and remnant log
| Field | Example |
|---|---|
| Source material | Plate PL-001; grade IS 2062; heat H778 |
| Cut plan | CP-44 revision 3 |
| Work order | WO-881 |
| Machine / shift | Laser L2 / shift A |
| Remnant | REM-044; 620 × 410 mm; Rack R4 |
| Process scrap reason | Outer trim and pierce waste |
| Rejected-part reason | Bend crack after cutting |
| Review owner | Production engineer; next run |
The next run should use the same denominator and material boundary. A lower scrap percentage on a different product or thinner gauge is not a like-for-like improvement.
Connect material and quality in Optiwise
Optiwise links material receipts, item identity, production orders, issue and return, quality inspection, rejection and stock movements. Configurable fields can keep cut-plan revision, remnant dimensions and cause data on the working records.
Follow the source material in inventory, work in production and rejected parts in quality. The stock-entry documentation is a primary reference for recording manufacturing material movements.
Choose the action from the cause
Nesting changes address cut-plan utilisation. Fixture or program corrections address repeatable geometry problems. Handling changes address scratches and dents. Material review addresses grade or flatness issues. Keep each action tied to the evidence that triggered it.
Questions from manufacturing teams
Should reusable remnants count as scrap?
No. Record a usable remnant as inventory with its identity, dimensions, quantity, condition and location.
How should sheet metal scrap rate be calculated?
State the boundary and denominator. In the example, process scrap is 7 kg divided by the 100 kg source sheet.
Can ERP optimise every nesting plan?
Do not assume that. ERP can connect material and production records; specialised nesting or CAD integration must be verified separately.
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