Optimization of Spool Fabrication Process

Spool manufacturing in a workshop environment is a preferred method in recent years for refinery and petrochemical plants. Spool manufacturing involves cutting and welding pipe and fittings in different length and quantities. It is aimed to have the least amount of loss when determining pipes to be cut for a spool. The purpose of this study is to optimize stock material usage to maximize spool quantity or Weld Dia Inch (WDI) total depending on the selected performance criteria. As part of a digital transformation project that covers all stages of the spool manufacturing process for a real factory, a Monte-Carlo algorithm has been developed to solve the optimization problem in the NP-hard category. Material Resource Planning (MRP) which provides the best performance criterion with minimum loss, is determined with the developed method