Cutting is where material yield is won or lost, quietly. A loose nest, a bad pierce, a re-cut for a poor edge — each leaves as consumed steel that never became a part, and as consumables burned reaching a cut that had to be done twice. The plate booked; the yield behind it did not.
Your ERP logs the plates cut and the steel issued.
It won’t tell you the nest ran loose all afternoon, or that a worn nozzle turned a clean shift into a re-cut one.
Why the gap existsWhere the losses hide
None of these stop the table. They show up as a slightly worse yield and a slightly higher consumable bill, and they average away by month-end.
The gap between the steel issued and the steel that became parts is real money, and it moves with nesting discipline and offcut reuse. Averaged over a month it is a percentage nobody owns; read per plate it is a habit you can see.
Nozzles, electrodes and gas are issued to the table and consumed against whatever runs. Per-metre or per-plate cost is the number that shows a worn consumable or a bad setting, and it is the one nobody has.
A poor edge, a bad pierce or a dross-heavy cut goes back for a re-cut or a grind. Real time and real consumable on a part that was already counted as done.
The join
Same run, same clock, same asset — three streams that only mean something together.
Plates and pipes cut, steel and consumables issued, jobs completed.
Consumption tied to the machine and the catalogued item, and the operator’s re-cut and nesting notes logged at the table.
Material yield and consumable cost read per plate and per job, with the re-cut that explains a bad one already attached.
What Munshi surfaces
Teal is normal, maroon is flagged. Illustrative data.
Two plates dropped well below the run. Both carry a nesting note logged at the table.
Tagged at the table, so the rework lands against the setting or the consumable that caused it.
When an outcome moves and a signal moves with it, Munshi shows both and says they moved together. It does not tell you one caused the other. The operator confirms the cause, and the confirmed cause is written back to that asset’s register — so the pattern is already named the next time it appears.
Related stages
The piece that came off the rolls to size — the second time.
Get started
See this on your own line.
Bring a month you already understand. The useful test is whether Munshi finds what you already know — and then what you didn’t.