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OPTI Filler Functionality

Garritt Corlett
  • Updated

Overview

The Filler functionality in FeneVision OPTI-GLASS and OPTI-BREAK is a yield-optimization feature that uses scrap space on glass cutting patterns to cut future production pieces. This functionality can significantly improve material yields by filling otherwise wasted areas on stock sheets with optional glass lites that don't need to be cut immediately.

Key Concepts

What is Filler?

Filler lites are glass pieces included in a release as "optional" production. If the optimization algorithm can place these pieces without increasing the number of patterns required, they will be cut. If placing them would require additional stock sheets, they will be removed from the release. Filler lites take priority over generating Store or Restock pieces.

Benefits:

  • Improves material yield by utilizing scrap space
  • Reduces overall glass waste
  • Allows future production to be cut opportunistically
  • No additional stock consumption when filler is successfully placed

 

Batch Mode vs. Dynamic Mode

The Filler functionality operates differently depending on whether your cutting machine is configured for Batch mode or Dynamic mode.

Batch Mode

In Batch mode, Filler lites are optimized together with production lites in FeneVision Opti-Glass before the release is sent to the cutting table.

How it works:

  1. Filler pieces are designated at the rack or individual lite level in Opti-Glass
  2. The optimization algorithm includes these as optional pieces during release optimization
  3. The resulting patterns with filler are sent to Opti-Break as-is
  4. Operators cut the patterns exactly as optimized in Opti-Glass

Dynamic Mode

In Dynamic mode, Filler lites are pulled onto patterns in FeneVision Opti-Break in real-time as production runs.

How it works:

  1. A separate "Filler Release" is created in Opti-Glass and marked as filler
  2. When running production releases at Opti-Break, filler lites are automatically pulled from the Filler Release into available scrap space
  3. Each pattern is re-optimized in real-time, allowing for maximum flexibility
  4. Filler lites can be pulled based on current conditions (remakes, inventory changes, etc.)

 

 Common Use Cases

  1. Filling Low-Yield Patterns: When a production release generates patterns with poor yield, filler can be used to fill empty space and improve overall efficiency.
  2. Future Orders: Include lites from future orders that aren't needed immediately. If there's room, they'll be cut early; if not, they remain available for later releases.
  3. Standard Sizes: Use filler to cut standard-sized pieces (common dimensions used frequently) that can be stored for quick fulfillment.
  4. Buffer Production: Build inventory of frequently-used items by marking them as filler across multiple releases.
  5. Mixed Priority Orders: Designate lower-priority orders as filler while ensuring high-priority orders are always cut.

 

Setup Instructions

Prerequisites

  • FeneVision Opti-Glass and Opti-Break must be installed and configured
  • Machine must be set up in Settings > Machines with appropriate optimization parameters
  • Inventory and part assignments must be configured

Setting Up Filler in Batch Mode

Step 1: Create a Release

  1. Navigate to Releases > Glass Cutting in Opti-Glass
  2. Select Add to create a new release
  3. Enter a Release Name and Description
  4. Select the cutting Machine
  5. Enter the Run Date

Step 2: Select Processes and Parts

  1. In the Processes tab, select the processes to include
  2. In the Part tab, select the glass types to include

Step 3: Designate Filler Racks

  1. Navigate to the Racks tab
  2. Locate the Filler checkbox column (appears next to the Select column)
  3. Check the Filler checkbox for entire racks that should be used as filler

Step 4: Designate Individual Filler Lites (Optional)

  1. If you want to use only some lites from a rack as filler, click the detail icon (pen and paper icon) in the rack row
  2. The Rack Details screen will appear
  3. Check Select for lites that should be production
  4. Check Filler for lites that should be optional filler
  5. Leave unchecked any lites not to be considered for this release
  6. Click Back to return to Rack Selection

Step 5: Optimize the Release

  1. Navigate to the Optimization tab
  2. Select stock sheets to use
  3. Configure Filler Mode in Machine Settings (if not already configured):
  4. Disabled: No filler lites will be placed
  5. Full: Filler lites used anywhere there is scrap
  6. Subplate: Filler lites only used within subplates (not outside final X cut)
  7. Click Optimize

Step 6: Review Results

After optimization, the pattern will show:

  • Production lites in aqua (default color)
  • Filler lites can be configured to display in a different color (orange in this example)
  • The optimization summary shows how many filler lites were successfully placed

Setting Up Filler in Dynamic Mode

Step 1: Create a Filler Release

  1. Navigate to Releases > Glass Cutting in Opti-Glass
  2. Select Add to create a new release
  3. Enter a Release Name (e.g., "Filler - Future Orders")
  4. Enter a Description (optional)
  5. Select the cutting Machine

Step 2: Mark as Filler Release

  1. In the Release Header section, locate the "Release as Filler" checkbox
  2. Check "Release as Filler (Dynamic Mode only)"
  3. Set the Run Date - typically set to a date in the future to indicate this is filler

 

Step 3: Select Processes, Parts, and Racks

  1. In the Processes tab, select the processes to include
  2. In the Part tab, select the glass types to include
  3. In the Racks tab, select the racks/lites to include in the filler release

Step 4: Optimize the Filler Release

  1. Navigate to the Optimization tab
  2. Select stock sheets
  3. Click Optimize

Step 5: Run Production in Opti-Break

  1. Open FeneVision Opti-Break
  2. Select a production release that contains the same glass type as your Filler Release
  3. Confirm that Include Filler is selected (toggle button on right side of screen)
  4. Select Run

Step 6: Verify Filler is Being Used

  • Once patterns generate, filler lites will appear in scrap areas
  • By default, both production and filler lites appear in aqua
  • Colors can be customized to differentiate (examples shows filler in orange)

 Configuring ForceFillerCompletionDate Parameter (Dynamic Mode)

This setup parameter controls how Filler Releases are treated relative to their Run Date.

Configuration Options:

Option 1: No Cut Deadline (Value = 0)

  • Filler Releases are treated as filler indefinitely
  • Filler lites only cut if no additional stock is needed
  • The Filler Release will never appear as a selectable release in Opti-Break
  • Use this when filler pieces have no deadline and should only be cut opportunistically

Option 2: Cut Deadline Enabled (Value = 1)

  • Filler Releases must be cut by their Run Date
  • Before the Run Date: Filler lites only cut if no additional stock needed
  • After the Run Date: All remaining filler lites will be optimized on the next run of that glass type, even if more stock is required
  • The Filler Release will appear in Opti-Break as a selectable release, allowing manual completion before the Run Date if needed

How to Configure:

This is a General Setup Parameter (GSP) configured in the FeneVision database. Contact FeneTech support for assistance in setting this parameter.

 

Configuring Filler Mode in Machine Settings

The Filler Mode setting controls how filler lites are placed on patterns.

Location: Settings > Machines > [Select Machine] > Optimization Tab > Filler Mode

Options:

1. Disabled

  • No filler lites will be placed on patterns
  • Use when filler functionality is not desired

2. Full

  • Filler lites used wherever they fit on the pattern
  • Maximizes filler placement
  • Fills all available scrap space

3. Subplate

  • Filler lites only used within subplates
  • Will not fill scrap outside the final X cut on a pattern
  • More restrictive than Full mode

 

 

 Visual Examples

 Filler Mode Comparison

Disabled Mode:

When Filler Mode is disabled, patterns contain only production lites with no attempt to fill scrap space.

Full Mode:

Filler lites (marked with 'F' in example) are placed anywhere there is available scrap space on the pattern. This mode provides maximum filler utilization.

Subplate Mode:

Filler lites are placed only within the subplate boundaries (the area between X-cuts). Scrap outside the final X-cut is not filled. This mode is more conservative than Full mode.

Filler Colors in Patterns

By default:

  • Production lites: Aqua
  • Filler lites: Aqua (same as production)

These colors can be customized in the database. In these examples, filler was configured to display in orange for demonstration purposes.

 

Troubleshooting

Issue: Filler checkbox not appearing in Racks tab

  • Solution: Verify machine is in Batch mode. The Filler column in the Racks tab only appears in Batch mode. In Dynamic mode, use "Release as Filler" checkbox instead.

Issue: Filler lites not being pulled in Dynamic mode

  • Solution:
    • Verify "Include Filler" is toggled ON in Opti-Break
    • Confirm the Filler Release contains the same glass type as the production release
    • Check that Filler Mode is set to "Full" or "Subplate" (not "Disabled")

Issue: All filler lites removed after optimization

  • Solution: This is expected behavior. Filler lites are optional – if placing them requires additional patterns/stock, they will be removed. Try:
    • Selecting different filler lites (smaller pieces)
    • Running smaller production releases to leave more scrap space
    • Reviewing yield settings

Issue: Cannot select Filler Release in Opti-Break

  • Solution: Check ForceFillerCompletionDate parameter. If set to 0, filler releases cannot be manually run. Change to 1 if you need the ability to complete filler releases early.

Issue: Filler Release disappeared from release list

  • Solution: In Batch mode, once a Store piece is consumed, the release may disappear to prevent deletion of used store pieces. This is expected behavior.

Important Notes and Best Practices

  1. Filler Priority: Filler lites take priority over generating Store or Restock pieces. If space exists, filler will be placed before remnants are stored.
  2. Optional Nature: Remember that filler is always optional. Don't rely on filler lites being cut by a specific time unless using ForceFillerCompletionDate with a deadline.
  3. Same Glass Type: In Dynamic mode, filler can only be pulled if the production release and filler release contain the same glass type (part).
  4. Run Date Strategy: For Dynamic mode filler releases, set the Run Date to a future date to clearly indicate these are filler items.
  5. Monitoring: Review optimization results to understand how many filler lites were successfully placed vs. removed.
  6. Machine Configuration: Filler behavior is controlled at the machine level. Different machines can have different Filler Mode settings.
  7. Batch vs. Dynamic: Choose the mode based on your operational needs:
  8. Batch: More predictable, patterns determined upfront
  9. Dynamic: More flexible, adapts to real-time conditions

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