Applied Math Problem - Creating A Cut List

I realize this gets into business logic, but a DB based solution might be best. Possibly some pre-calculated measurement tables.

Business problem: Creating a cut list for a window covering (blinds) system. It's preferably a fast calculation I could execute while the user awaits "order confirmation and pricing". A .5 second delay per order would be acceptable.

An order can have unlimited number of line items, but typically between 1 and 20 (number of windows in a single house).

(For this problem) the raw material is man-made, and therefore is always the same length for a particular pattern/color (take 12' for this example; we stock patterns in 9', 12', or 16' but it's always the same for a given pattern/color). I need to tell the cutters how to use the rawmaterial with minimal waste. Note: The saw blade takes 1/16th inch.

For each line item; I have pre-calculated the exact cut size and number of slats. Measurements are in inches at 1/8 (.125) inch increments. The length of raw material length we stock for this pattern is an easy link.

The goal is to average less than 6 inches waste per 12' piece of raw material.

Example order:

5 line items for pattern/color FAUX/white, stocked in 12' lengths.

Line 1: 34 slats at 35.125 inches.
Line 2: 36 slats at 36.875 inches.
Line 3: 50 slats at 42 inches.
Line 4: 55 slats at 70 inches.
Line 5: 52 slats at 30 inches.

The resulting cut-list-workorder would evaluate all lines together and tell them how many 12' slats to pull and how to cut them with minimal material waste.


My question:

I'm left wondering if a database style pre-populated answer list (or some other database based solution) might be a lot faster and simpler than some chess-style complex trial-and-error array based VB algorythm (that I haven't even begun to imagine how to write). If so; how would it look?

In addition; the cutters get something like $10/hr so we can't make it too complex. I'd rather waste a little material and avoid undue confusion, but not much. With $5+ million in this material per year, excess waste can really add up. Imagine the difference between 12% and 15% waste. It's an area worth investing in.

Sorry; I know it's not a simple question. Someone might find it interesting enough to solve, or at least provide hope for a DB solution. At present; I just can't imagine it.