REDUCE MANUFACTURING COSTS WITH YOUR EXISTING CUTTERSIdentify room for improvement in your automotive cutting room

By eliminating the root causes of operational losses, Lectra can incrementally increase the capacity of your installed base to reduce your manufacturing costs.

EVALUATE YOUR CUTTING ROOM PERFORMANCE AND PINPOINT HIDDEN LOSSES WITH A LECTRA HEALTH CHECKLOSSES YOU’RE AWARE OF ARE JUST THE TIP OF THE ICEBERG

Material lossesHave you already identified pathways to improvement to reduce your material consumption? Did you know that a 1% reduction in material can result in up to €100K in savings per year?

Inefficient processesDo you track every minute of your machine’s downtime? Are you aware that eliminating downtimes due to inefficient processes can potentially increase cutter availability by 50%?

Underutilized assetsAre your machine settings optimized for each production order? Do you know how to maximize cutting speed and spreader height without lowering production quality?

Non-quality lossesDo you monitor the impact of non-quality in cutting room inefficiency? Did you know that eliminating even a small number of recuts can have major impact on asset availability?

hIddeN Losses

MaterIaL Losses

UNderUtILIzed assets

NoN-QUaLItY Losses

INeffIcIeNt processes

LECTRA HEALTH CHECK: A FIRST STEP IN YOUR JOURNEY TO OPERATIONAL EXCELLENCE How can you increase your performance in the cutting room? What are the root causes of equipment unavailability? How can you reduce your fabric consumption? Read on to see how Lectra answers these questions, by showing the results already achieved for customers worldwide.

TURN NON-VALUE-ADDED ACTIVITIES INTO LEAN OPERATIONS

By drilling down into the exact causes of availability losses, Lectra can help you identify non- value-added activities and maximize machine cutting time. For a customer in Mexico, by using lean manufacturing tools and real data extracted from the machines, Lectra increased machine availability from 56% to 80%.

LEVERAGE ALL PATHWAYS TO MINIMIZED MATERIAL LOSSES

By analyzing actual material consumption in-depth, Lectra can help you identify, track and minimize material losses using gap reduction, nesting optimization and process improvements. For a customer in Europe, by reducing buffer between pieces from 5mm to 2mm, improving spreading, optimizing marker length and compensating roll width variations, Lectra reduced fabric consumption by 2.5%, saving €250K annually.

USE A COMPREHENSIVE APPROACH IN THE ANALYSIS OF NON-QUALITY

By identifying the causes of non-quality and the related impact on cutting room efficiency, Lectra can help you focus on critical issues you need to improve. For a customer in Asia, Lectra was able to determine that 1.9% of recuts were consuming 8.8% of machine availability. By analyzing root causes, Lectra found that 35% of non-quality was due to inappropriate settings and the machine’s state of repair.

HARNESS THE FULL POTENTIAL OF ASSETS TO MAXIMIZE PERFORMANCE

By optimizing the advanced parameters of your equipment, Lectra can help you optimize cutting speed and the total number of plies cut without lowering production quality. For a customer in Mexico, Lectra optimized the advanced parameters to increase the total number of plies by up to 109%, contributing to an overall increase in capacity from 550 to 825 car seat sets per day that resulted in a $Us 0.20 reduction in cost per seat set.

WHY LECTRA?

Lectra’s multidisciplinary teams bring significant field experience to each customer project. Their high-leverage skill sets help our customers quickly identify pathways to improvement and implement operational solutions to business challenges. Our Lean Business Consultants all have an automotive industry background and are recognized specialists in their customers’ line of business. Together with our Solution Consultants and Technical Specialists, they contribute to the implementation of operational excellence projects designed to meet customer challenges.

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