Cut List SOP

This procedure defines how Blitzpanel translates a released panel design into wire and wire-duct cut lists that drive wire prep and kitting.

It exists to ensure every wire is cut to the correct length, carries the correct label/wire number, and is staged in the sequence the build requires.

A disciplined cut list reduces re-work from short or miscut wire, keeps wire prep and kitting synchronized with the released BOM, and preserves wire-to-schematic traceability for UL508A documentation.

Applies to all released panel designs (schematic, panel layout, and BOM) moving into production, covering point-to-point wiring, subpanel interconnect wiring, and wire duct/raceway routing.

Covers extracting wire runs from the released design, calculating cut lengths, assigning labels/wire numbers, batching the cut list by job, and releasing it to Wire Prep and Kitting.

Does not cover schematic/BOM creation itself (see Engineering Release SOP) or physical wire termination, dress, and test (see Wire Prep SOP).

Cut list — the itemized list of every wire/cable segment required for a panel, with wire number, gauge, color, length, and label for each end.

Cut length — the length a wire is cut to, derived from the routed point-to-point distance plus slack allowance and rounded to the shop's standard increment.

Wire number / wire label — the identifier from the schematic that is printed on a heat-shrink sleeve or wire marker at each termination point.

Slack allowance — extra length added beyond the measured routing distance to account for dress, service loops, and rework at terminations.

Wire duct fill — the percentage of a wire duct's cross-sectional area occupied by wire, used to confirm the assigned duct size is not overfilled.

Role	Responsibility
Design / Engineering	Releases the schematic (with wire numbers), panel layout, and BOM used to generate the cut list.
Cut List Preparer	Generates the cut list from the released design, applies length and labeling rules, and batches it by job. TODO: confirm the role/title that owns this step.
Wire Prep Technician	Cuts, strips, and labels wire per the cut list; flags discrepancies back to the Cut List Preparer.
Kitting	Stages cut, labeled wire in job-specific kits and confirms the batch count against the cut list.
Quality	Verifies wire marking, gauge/color, and cut-list-to-schematic agreement before batches are released to the build.

Cut list generation tool or spreadsheet template. TODO: name the current Blitzpanel cut-list system/template.

Automated wire-cut and wire-marking machine used for batch cutting and labeling. TODO: confirm make/model and its import format for the cut list.

Label/marker printer and wire-marker stock for terminations not produced by the automated machine. TODO: confirm printer model and label stock.

Wire duct fill calculation reference for the duct sizes used in current panel designs. TODO: attach or link the duct fill reference/chart.

Wire and label stock (gauge, color, insulation type) per the Approved Vendor List SOP.

6.1 Extract wire runs from the design

Confirm the design package is released and complete: schematic with wire numbers, panel/sub-panel layout, and a BOM revision that match each other.

Extract every wire run (point-to-point connection) from the schematic, recording wire number, gauge/color, from/to terminal, and conductor count.

Cross-check the extracted wire run count against the schematic's wire-number list to catch missed or duplicate runs before proceeding.

6.2 Calculate cut lengths

Determine the routed distance for each wire run from the panel layout drawing and the wire duct path — not the straight-line distance between terminals.

Add the standard slack allowance to the routed distance to arrive at the cut length. TODO: define the standard slack allowance (e.g., inches per termination and per duct turn).

Round the resulting cut length up to the shop's standard cutting increment. TODO: define the rounding increment (e.g., nearest 1/2 in).

Flag any run that exceeds the maximum single-length wire spool or would require a splice, and route it to Design/Engineering for review before cutting.

6.3 Assign labels and wire numbers

Assign each cut wire the wire number/tag shown on the schematic; do not renumber or reassign wires during cut-list generation.

Record gauge, color/insulation type, and voltage rating on the cut list entry, matching the schematic and BOM exactly.

Generate a wire label/marker for each end of the wire consistent with the applicable wire-marking requirement. TODO: verify the exact UL508A wire-marking/labeling clause before citing.

Check the running wire duct fill against the maximum allowed fill percentage for the assigned duct size before finalizing the cut list. TODO: confirm Blitzpanel's maximum duct fill percentage standard.

6.4 Batch and release the cut list

Group the cut list by job/panel and, for multiple units of the same design, by build quantity to enable batch cutting.

Sequence or tag the cut list by wiring zone or panel section to match the build sequence used on the floor. TODO: confirm the build sequencing convention used in the shop.

Set the cut list revision to match the schematic/BOM revision it was generated from; increment it on any wire-number or routing change.

Release the finalized cut list to Wire Prep and Kitting together with the panel layout and wire number list.

6.5 Feed wire prep and kitting

Wire Prep pulls wire stock per the cut list, cuts each run to its specified length, strips ends, and applies labels/markers at each end.

Kitting stages the cut, labeled wire in job-specific kit containers or bags, cross-referencing the batch against the cut list count.

Wire Prep and Kitting flag any shortfall, miscut, or mislabeled wire back to the Cut List Preparer before the kit is released to the build.

Record the completed cut list batch as ready for build and update job status. TODO: name the system of record for job/production status.

The cut list itself (revision-controlled), tied to the schematic/BOM revision it was generated from.

The wire number list/schematic reference used to generate the cut list.

Any cut list deviation or engineering flag raised for oversized, spliced, or non-standard runs.

Retention period for cut list records. TODO: set retention policy.

Wire Prep SOP, Kitting SOP, Engineering Release SOP, Approved Vendor List SOP.

UL508A — Standard for Industrial Control Panels (wire marking/identification basis). TODO: verify exact clause references before citing.

NEC / NFPA 79 — conductor ampacity and wireway/duct fill basis. TODO: verify exact clause references before citing.

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