Lectra Manufacturing Expertise Optimize the use of material.

Lectra Manufacturing Expertise

Optimize the use of material

We all face similar challenges

Import growth

Stronger and more competition

High labor cost

Social responsibility

Sustainability

Increased raw material costs

Need to differentiate

Drop of consumer trust and loyalty

Reduce time to market

Design value

Brand value

New sale channels

Innovation

Eco-friendly materials

Customization

Key drivers to Control Raw material consumption

1Product & material specifications

2Scheduling & marker-making methodology 3Production

Practices & accuracy

4Hide management




practices & accuracy

4Hide management

How much change decision impacts the R&D costs

How much change decision impacts end-product cost

Sketches Wood structure Foams Upholstery Costing

Physical prototyping assembly

Industrialization

DE

CIS

ION

-MA

KIN

G

70 to 80% OF THE END-PRODUCT COSTS ARE DECIDED AT THE DESIGN STAGE

Management method for innovation and product development

Product m

odifications

Production

Design to C

ost

1 Model10 Models

100 Models

71.1 %72.8 %72.7 %

71.7 %73.6 %73.2 %

70.4 %71.6 %71.6 %

73.2 %75.5 %75.5 %

Option 1 Option 2 Option 3 Option 4

Marker Efficiencies

For each design option

PRELIMINARY DESIGN & INTERACTIVE COSTING

FABRIC & LEATHER CONSUMPTION, LABOR COSTS





4Hide management

Trade off between

fabric cost and inventory

CuttingDriven by process optimization

SewingDriven by demand

Decoupling point

Longer markerMix big and small pieces

Lot sizeCost optimization

One piece flowAdapt to change in demandSpeed

Context• Furniture in Scandinavia• Lectra was asked to

optimize the cutting room process

Methodology• Review the fabric ordering

process• Reorganization of costing and

fabric ordering• Combine orders to reduce

fabric consumption

Raw material use - Customer case 2

Validated fabric savings 8.6% / 49k€





4Hide management

ACCURACY

Cutting tool

Machine condition

Skills

Alignment

Transportation

Length control

Fabric ConsumptionProduction practices & accuracy

Spreading and cutting practices

179

180

181

182

183

0 1 2 3 4 5

Roll width variation Width EfficiencyMarker length

1.80 83.79% 6.5m

1.81 83.79% 6.46m

1.82 85% +1.2% 6.33m

1.8388%

+4.2%6.08m

Use maximum of roll width


“ New settings can reduce gaps between pieces (from 5mm to 2mm or even zero buffer) ”

“Spread length doesn’t match the expected value, variation from 0.5% up to 3%, estimated impact 400k€.”

“Optimized roll handling to use material to the full. There is a 1.5% fabric width variation.”






4Hide management

Quality zone definitionDevelopment Production realityGAP

Cushions Quality A

Arm rest Quality A and B

Back/side Quality A/B

Seam: not always defined

Correct separation visible/hidden not clear

Cushions Quality A Hidden B seam C

Arm rest Quality A and B hidden B Seam C

Back/side Quality B hidden and Seam c

Seam: defined and accurate

Always measure visible/ non visible

Material ConsumptionHide management

Transport

Packaging

Reception

Sorting

conditions

Sorting

Environme

nt

Allocate

hides

Distribution

Small/Big

Crates

Put quickly onto

horses to flatten the

hide

Lighting: mark hidden defects

Quality control

and A and B hides

Temperature and humidity

Have ratio for

A/B hides

Ergonomy in

using the hides

Hide reception and handling

Material ConsumptionHide management

To reach operational excellence

Our approach

LECTRA’S CONSULTING EXPERTISE

Product development efficiency

Raw material optimization

Cutting room performance

BASED ON 40 YEARS OF EXPERIENCE IN YOUR

INDUSTRY

FLOW and LAYOUTDESIGN FORMANUFACTURING

FABRIC/HIDECONSUMPTION

OPERATIONALAVAILABILITY

PERFORMANCECUTTINGQUALITY

Our Expertise in Manufacturing

Reduce lead timeReduce non value added activitiesOptimize space and motion

Reduce material costs

Improve efficiency

Improve performance

Reduce non quality costs

Reduce industrialization costs and lead time

DESIGN/STYLE PROTOTYPES DEVELOPMENT PRODUCTION

FLOW and LAYOUTDESIGN FORMANUFACTURING

FABRIC/HIDECONSUMPTION

OPERATIONALAVAILABILITY

PERFORMANCECUTTINGQUALITY

… by improving processes, skills and organization

Reduce lead timeReduce non value added activitiesOptimize space and motion

Reduce material costs

Improve availability

Improve capacity

Reduce non quality costs

Reduce industrialization costs

DESIGN/STYLE PROTOTYPES DEVELOPMENT PRODUCTION

People skills

Process efficiency

Monitoring system

Working procedures and data quality

Productivity

Organization maturity

TimeQuality

Cost

Our team

BUSINESS CONSULTANTS1SOLUTIONS EXPERTS2CUSTOMER CARE3

Help our customers analyze and redesign processes and organization, referring back to your business best practices

Design and implement solutions per a customer’s unique requirements, in line with projected timetable & operational objectivesHelp develop the skills to use the proposed solutions

Provide operational assistance to our customers to ensure maximum efficiency and level of service

OUR MISSION

Respond to the constant need to combine quality, creativity & flexibility, streamline

processes, and safeguard margins & competitiveness

throughoperational excellence

““BY CHANGING NOTHING,

NOTHING CHANGES

THANK YOU

Lectra Manufacturing Expertise Optimize the use of material.

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