Arthur Ria
18 KiB
title, type, sources, related, last_compiled
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2026-04-10 |
Cutting Stock
Overview
Cutting stock is a specialization of item management for items that are measured and cut to order rather than picked in discrete unit quantities. Examples: rope, electric cable, chain, flexible pipe (hose), fabric rolls, wire. These items exist as continuous rolls or coils and can only be shipped in specific lengths.
Cutting stock is an exclusively manual warehouse feature — not supported in automated or semi-automated warehouses.
By definition: a cutting item is any item with an assigned cutting profile. The profile defines how the item behaves: whether it requires a cutting station, how it's labeled, and how its stock consolidation works.
Core Concepts
The Non-Consolidation Rule
The defining characteristic of cutting stock is that its base UoM conversion does NOT consolidate. This means:
- Multiple stock lines of identical qualities (same item, lot, status, logistic attributes) can coexist in the same location/container as separate records — they are never merged.
- Each stretch is an individual record with its own quantity (length).
- This enables precise tracking of available stretch lengths.
Practical implication: If you have three 30m rolls of the same cable in the same location, you have three separate stock records (30m, 30m, 30m) — not one 90m record.
Base UoM Rule
The base UoM of a cutting item must be the smallest unit in which the item is allowed to be cut (no decimals supported). For example: if the minimum cut is 1 meter, the base UoM is meters with integer precision.
Non-Consolidating Conversions
A UoM conversion (presentation) on a cutting item can be marked as "Do not consolidate" independently. When active:
- Multiple stock lines of the same conversion coexist without merging
- The item follows all cutting-stock rules for that conversion
- All conversions except the base must be of type presentation with the "Allow splitting" flag active (to enable partial-length cutting)
Cutting Profile
The cutting profile is what transforms a regular item into a cutting item. It defines behavior for the entire lifecycle.
Cutting profile attributes:
| Field | Description |
|---|---|
| Code | Unique profile identifier |
| Description | Free text |
| Default | If flagged, automatically assigned to new items |
| Labeling source stock | Generate label for the roll from which stock was cut |
| Labeling cut stock | Generate label for the cut portion |
| Cutting in station | False = cut on the shelf; True = cut at a designated cutting station |
| Mode of picking process | When "Cutting in station": Integrated (same operator does supply + cut + pick) or Delegated (separate operators for each step) |
| Associated cutting stations | Which cutting station(s) this profile can be processed at |
Multiple cutting profiles can share a cutting station. However, sharing stages between stations is only advised when both stations cut the same cutting profiles.
ERP creation: Cutting profiles can be created (not modified or deleted) from ERP via the ITM message.
Interface: View "Cutting profiles" in menu "Masters > Item details".
Configuration Steps (First-Time Setup)
- Create a cutting profile (define labeling, station/shelf mode, associated stations)
- Assign cutting profile to the item (makes it a cutting item)
- Configure item as non-consolidating conversion (flag "Do not consolidate" on relevant UoM conversions)
- Set stock assignment strategies (minimum and maximum shipping quantity fields on item master)
- Configure shipping profile for the item (excess percentage + enter quantity mode = "Manually")
- If cutting in station: configure cutting stations in EasyS (stages, routes, station type 61)
Stock Assignment Strategies
Two parameters on the item master control how stock is assigned to shipping order lines. Only applies to non-consolidating conversions.
Continuous Stretches (Maximum Quantity set)
Set "Maximum shipping quantity per line" = length of the longest roll presentation (in base UoM).
- Requested length ≤ maximum → assigned in one single stretch (guaranteed)
- Requested length > maximum → assigned as X complete rolls (= maximum) + one continuous stretch for remainder
Example: Max = 100m, required = 125m → assign 1 full roll + 25m stretch
Segmented Stretches (Maximum Quantity empty)
No maximum set. System tries to supply with as few stretches as possible, but no guarantee of a single continuous stretch.
Example: Stock = 30m+30m+30m, required = 70m → assign 30m + 30m + 10m cut from third roll
Minimum Cutting Quantity
The "Minimum shipping quantity" field sets the minimum length to cut. Any requirement below this minimum is automatically rounded up.
Example: Min = 10m, required = 5m → assign 10m stretch
Exception 1 (with maximum): If maximum is set and surplus < minimum, also rounds up. Max = 100m, Min = 10m, required = 105m → assign 100m roll + 10m stretch
Exception 2 (no minimum stock available): If minimum is set but no stock line has length ≥ minimum → assign the group of stretches closest to minimum, without cutting. Min = 10m, required = 9m, stock = 3m+4m+8m → assign 8m+3m=11m, no cut
For exception 2: the shipping profile's "Excess Pick Percentage" must be empty.
Note: For cutting in station, stock in cutting station stages is prioritized over warehouse stock.
Cutting Stations (Type 61)
Cutting stations are where cutting-in-station processes are executed. A cutting station consists of:
- Receiving stage: Holds rolls assigned for cutting
- Shipping stage: Holds cut portions ready for shipping or return to warehouse
Configuration options:
| Configuration | Use Case |
|---|---|
| Single stage (receive + ship) | Item cut multiple times per day, rarely returned to warehouse |
| Two dedicated stages per station | Item cut a few times per month, returned to warehouse after each cut |
| Two shared stages across multiple stations | Multiple nearby stations cut the same profiles |
Cutting station can be locked via "Stations" view to prevent new stock assignments.
Required EasyS configuration:
- Station type 61 (Cutting)
- Single buffer location per station, storage mode = stock, allow picking
- Routes: station ↔ stages, station ↔ equipment, station ↔ warehouse, stages ↔ docks/stages/consolidation
- Associated stages: routes to cutting station, other stages of same station, stages of stations cutting same profile, equipment, warehouse, docks/stages/consolidation
Label recommendations at cutting stations: Print labels for cutting station code, station location code, receiving stage location code, shipping stage location code — operators confirm these codes continuously during cutting.
Reception of Cutting Stock
Blind Reception (Loose Stock)
Process for receiving multiple rolls of different or identical lengths in non-consolidating conversions.
Use cases:
- Variable-length rolls: Receive one roll at a time, each with its own length record. Repeat as needed.
- Multiple identical rolls (Multi): "Multi" action creates multiple records of the same length simultaneously.
- Edit or delete rolls: View and modify all lines created for an item + conversion in the receipt; edit quantity or delete lines.
- Receipt and putaway: When receiving loose cutting stock in equipment, can immediately putaway. Must confirm exact length of each roll for unloading confirmation.
Transactions: STK.RECEP (per stock line), CON.RECEP (per container if applicable)
ERP Communication: REF message sent at receipt close
Supplier Receipt in Stage
Receive cutting stock rolls at a receiving stage. Stocks in non-consolidating conversions are recorded individually (not summed). Supports individual roll reading and "Multi" for same-length batches.
Interface: RF menu "Receipts > Supplier" → "Loose stock/Multi-reference"
Receipt-and-Putaway Specifics
Due to non-consolidation, when selecting a stretch to unload and confirming unloading, the exact length of each roll must be confirmed. This is stricter than regular container unloading.
Picking and Cutting Processes
Shelf-Based Cutting (cutting_in_station = False)
The operator cuts directly at the shelf location. The picking process is the same as standard picking with the difference that:
- The exact length to cut is confirmed manually
- "Enter quantity mode" must be set to "Manually" in the item's shipping profile
- System never allows picking less than ordered; overpicking is controlled by "Picking excess percentage" in shipping profile (0 = no excess; blank/100 = excess allowed)
Integrated Cutting in Station
Same operator does supply, cut, and pick as a single workflow within the normal picking process.
Three-phase process:
- Supply: If stock is not at the cutting station's stages → system guides operator to pick the roll from warehouse and bring it to the receiving stage. Operator can also pre-supply manually via Manual Movement.
- Cutting: At the cutting station, operator cuts the required length. System guides confirmation.
- Labeling: If cutting profile has labeling flags → labels are printed for cut stock and/or source roll.
Station (integrated) items can be included in shipping orders, order groups, and waves.
Monitoring: Supervisors can monitor line and order status from web interface.
Return to warehouse: Operator can return stock without pending assignments from station to warehouse at any time.
Note: Once a cutting stock line has tasks in "In Process" or "Finished" status, quantity cannot be changed — but line can always be canceled.
Delegated Cutting in Station
Separate operators handle supply, cutting, and shipping as independent process steps.
Multi-phase workflow:
- Supply: Operator brings assigned rolls from warehouse to cutting station receiving stage (via picking order RFT or automatic tasks). Manual supply also supported via Manual Movement.
- Cutting: Dedicated cutting operator executes cut at station, adds labels, identifies which stretch to cut first (can view cutting tasks accumulated per item with priority list).
- Shipping/Palletization: Operator takes cut stock to destination (dock/stage/consolidation). If the roll itself is a shipping container, it can be palletized.
Not supported in groupings or waves (unlike integrated mode).
Return to warehouse: Unassigned stock can be returned to warehouse at any time.
Cutting Excess and Shipping Profile
Two critical shipping profile settings for cutting items:
Overpicking Configuration
| Setting | Shipping Profile Config | Effect |
|---|---|---|
| Allow overpicking | "Picking excess %" = null or 100 | Over-picked stock not flagged as excess at shipping |
| Disallow overpicking | "Picking excess %" = 0 | Exact quantity required; any excess raises error |
Because cutting requires tools and cannot be performed everywhere, it is not possible to undo preparation or remove excess except by cancellation.
Enter Quantity Mode
Cutting stock is indivisible — you cannot pick one unit at a time to confirm total. Therefore:
- "Enter quantity mode" must be set to "Manually" in the item's shipping profile
- The total length is confirmed in one step at the moment of cutting
This is mandatory for correct cutting stock behavior.
Counting Cutting Stock
Counting cutting stock (in non-consolidating conversions) differs from standard counting. Only supported in manual warehouses.
"Stretch" = any non-consolidating cut-off stock record in UoM.
Three counting use cases:
-
Count multiple stretches continuously: After entering item + UoM, operator reads stretches continuously without re-entering item code. "Done" saves all records. "Stretches" action shows running count list.
-
Assign user status during counting: Set status before entering a stretch; status persists for subsequent stretches until changed or removed. Can be assigned/unassigned to any stretch in the list.
-
Modify counted lines: Delete any stretch (not edit quantity — deletion only). "Stretches" action lists all counted stretches. "Empty List" action clears all. Lines with user status are shown in list.
Informed count mode: For locations where exact roll lengths are unknown. Verifies bulk presence only. Allows comparison and adjustment by operator.
Transactions: ADJ.STK (stock adjustment), CON.CREATE, CON.DELETE
ERP: STV (stock variation), STC (status change). If count created from ERP COR → response via COF.
Quality Control Lock
See quality-control for full details. Cutting stock has specific lock behaviors:
- Partial lock: Lock a specific stretch (individual stock record)
- Total lock: Lock entire coil/roll
- When locked stock is split by a cut: lock propagates to cut portion
- Lock from RF terminal or ERP
- ERP messages: STR (status lock/unlock), STC (status change notification)
Manual Movements
See manual-movements for full details. Specific cutting stock rules:
- Cutting stock moves require exact stretch length confirmation
- Moving cutting stock is only allowed as a whole stretch — partial moves of a stretch are not supported (the indivisibility rule)
- If move requires cutting to reduce length, that is not permitted via manual movement — must go through the picking/cutting process
Crossdocking Interaction
Cutting outside storage locations is not permitted. However, opportunity crossdocking is possible for cutting items in non-consolidated conversions, depending on the cutting item configuration. The crossdocking process must be explicitly enabled and configured per item.
Stock Adjustment for Cutting Stock
See stock-adjustment for full details. Cutting-specific behavior:
- Adjustments apply to individual stretch records
- Labels can be printed for cutting stock from the "Location adjustment" RFT process — only if the cutting profile has "Label source stock" active
- Transactions: STK.ADJ
Parameters
| Parameter | Default | Description |
|---|---|---|
| CUTTING_PRINTER | (blank) | Default printer for cutting stock labels during picking. See parameters. |
Interface
| Process | Interface | Equipment |
|---|---|---|
| Configure cutting profiles | Masters > Item details > "Cutting profiles" | PC |
| Configure cutting items | Masters > Items | PC |
| Configure conversions (non-consolidating) | Masters > Conversions | PC |
| Configure cutting assignments | Masters > Items | PC |
| Configure shipping profile | Masters > Item details > Shipping profile | PC |
| Blind cutting stock receipt | Receipts > Blind > Loose stock/Multi-reference | RFT |
| Supplier cutting stock receipt | Receipts > Supplier > Loose stock/Multi-reference | RFT |
| Cutting stock picking (shelf) | Picking orders | RFT |
| Integrated cutting in station | Picking orders (same as standard picking) | RFT / Label printer |
| Delegated cutting supply | Shipping orders > Picking order OR Tasks > Automatic mode | RFT |
| Delegated cutting execution | Cutting menu > Cutting | RFT |
| Cutting stock count | Counts > Physical count / Guided count | RFT |
| Print cutting label from stock view | Warehouse > Stock > "Print cutting label" action | PC |
| Print label from location adjustment | Utilities > Location adjustment | RFT |
| Monitor station orders | Shipping orders view | PC |
Common Errors
| Error | Cause | Solution |
|---|---|---|
| Cannot change quantity on cutting line | Task is In Process or Finished | Cancel the line instead; excess cannot be undone |
| "Minimum cutting quantity" not respected | Shipping profile "Excess Pick %" has a value | Clear the Excess Pick % field when using minimum cutting quantity |
| Stock not assigned as single stretch | Maximum quantity not set in item master | Set "Maximum shipping quantity per line" to longest roll length |
| Delegated cutting line not included in wave | Delegated items not supported in waves/groups | Use only integrated mode for order groups and waves |
| Labels not printing during cutting | Cutting profile lacks labeling flags | Check "Labeling cut stock" and "Labeling source stock" flags in cutting profile |
| Count treats cutting stock like regular stock | Item UoM not flagged "Do not consolidate" | Ensure non-consolidating flag is active on relevant UoM conversion |
Related
- product-item — Cutting profile is configured on the item master; base UoM rules apply
- reception — Cutting stock has specialized receipt processes (blind, supplier)
- picking — Integrated and delegated cutting processes are extensions of picking
- shipping — Shipping profile configuration is mandatory for correct excess handling
- stock-adjustment — Label printing from location adjustment; STK.ADJ transactions
- count — Counting stretches has unique UI and process rules
- quality-control — Cutting stock locks (partial/total); STC/STR messages
- manual-movements — Moving whole stretches; indivisibility enforced
- stations — Cutting station (type 61) configuration and associated stages
- labels — Cutting stock label format (A6), print triggers, printer priority
- parameters — CUTTING_PRINTER parameter