Sheet Metal Stamping & Press Lines worked example

Blank Size Optimization at 65% nesting layout efficiency: a worked example

Suppose nesting layout efficiency falls to 65%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Blank size optimization is about getting the maximum number of usable blanks out of every sheet or coil by choosing the right blank dimensions, orientation and nesting pattern.

The inputs for this scenario

  • Optimized blanks nested from stock: 1,200 units (held at the documented default)
  • Sheet or coil processing time: 8 hr (held at the documented default)
  • Nesting layout efficiency: 65 % (the input this scenario stresses; the baseline uses 90)

Working through the calculation

  • The calculation starts from the formula this tool documents: Raw blank size optimization = completed output รท runtime.
  • Effective throughput works out to 97.5 units at these inputs, and this is the headline figure for the scenario.
  • Raw throughput works out to 150 units at these inputs.
  • Efficiency works out to 65 % at these inputs.
  • Runtime works out to 8 hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where nesting layout efficiency sits at 90% and the headline result is 135 units, this scenario comes in 27.78% below the baseline at 97.5 units.
  • It converts blanks produced and processing hours into a blanks-per-hour rate, then applies nesting efficiency to give the effective throughput of the optimized layout. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Effective throughput: 97.5 units (headline result)
  • Raw throughput: 150 units
  • Efficiency: 65 %
  • Runtime: 8 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Blank Size Optimization calculator, set nesting layout efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.