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June 12th, 2019
Seating & Interior TrimDevelop, Cut & Optimize with Digital Processesto Lower Your Cost per Car Set
Jim Collins Graeme StewartVP Automotive Sr Director, EngineeringLectra Tachi-S USA
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Today’s Speakers Jim Collins (Lectra) and Graeme Stewart (Tachi-S)
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Graeme (left) and Jim (center) at the 2019 WardsAuto Interiors Conferencefeaturing the Nissan Kicks driver’s seat from the 10-Best Interior,
produced by Tachi-S using Lectra digital technology.
Jim Collins is Lectra North America’s automotive team leader.
Over the past 30 years, Jim initially held key roles in the marine industry for 10
years and then moved into automotive including nine years at Lectra.
With deep knowledge and expertise in the digital cutting room, Jim provides
invaluable strategic and tactical insights to our global automotive customers.
Graeme Stewart is Tachi-S USA’s Senior Director of Engineering.
With over 30 years of seating experience, Graeme knows what it takes to create safe, stylish and comfortable automotive seats.
He has led multiple seating programs for various OEMs including: Acura, Daimler, Freightliner, Honda, Infiniti and Nissan.
Graeme oversees all of the company’s engineering, program management and benchmarking efforts.
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Who is Lectra? The global market leader in the digital cutting room technologyThe Automotive Interior has become the convergence of fashion, comfort and safety
Lectra’s largest and fastest growing business is Automotive
Fashion AutomotiveFurniture
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SEATING AND INTERIOR TRIM
AUTOMOTIVE LEATHER
AUTOMOTIVE AIRBAG
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Lectra AutomotiveServing 3 Market Segments with digital performance
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TACHI-S CO., LTD
• Global supplier
• 64 years experience
• $2.7 billion in global sales
• $80 million in capital
• 12,356+ employees
• Tokyo Stock Exchange / First Section (Securities Code: 7329)
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WardsAuto Lectra Webinar
TACHI-S Global Footprint
13 Countries, 54 Business Entities
ISUZU
HINOMITSUBISHI
UD TRUCKS
NISSANHONDA TOYOTA
GEELY CHERY
CUSTOMERS
RENAULTDAIMLER
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For 2019, 7 of the 10 Best Interiors were “Made with Lectra”The Nissan Kicks seating crafted by Tachi-S
• Bentley Continental GT
• BMW M850i
• Genesis G70
• Hyundai Santa Fe
• Jeep Gladiator
• Lincoln Nautilus
• Mercedes Benz A220
• Nissan Kicks
• Toyota RAV4
• Volvo V60
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Focus on Digitalization + Risk Management = PerformanceAlign your operations with your customers’ initiatives
• Operational Excellence
• OEE
• Maintenance
• Overall uptime
• Predictive analytics
• Risk management
• Digital acceleration via technology & innovation
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OESA OEM TownHall Jan 29, 2019
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Industry 4.0 & Digital Acceleration – Optimize the Supply ChainBring new products to market faster + easily manage a larger portfolio of trim levels
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Industry 4.0 – Performance Optimization results in cost savings across your operations3 common goals from our customers
Note: a survey of 300 participants from three countries (the US, Germany, and Japan) across various manufacturing industries, supplemented by in-depth interviews with industry thought leaders and extensive research.
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Digitalization through Industry 4.0Integral for businesses to face market challenges
Demand for more personalization
Changing mobility habits
Interiors as differentiatorsNeed for digital, integrated experience from shopping to life on boardCompetition among suppliers
Greater production complexity
Cost pressure
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Partners in Industry 4.0 – ConnectedHigh Speed Flexibility to produce more trim levels, faster
Lectra’s strategy empowers our
customers, like Tachi-S, through
digitalization as they step into
Industry 4.0
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Market Challenges, Goals & Actions – Optimize Performance
CHALLENGES GOALS ACTIONS
Quicker deliveries
Pressure on prices
Higher quality
standards
Increasing demand for
customization & model diversity
Reduce time to market
Anticipate and reduce coststo increase margins
Increaseproductquality
Increase efficiency in
manufacturing with flexibility
Manufacturing process optimization & flexibility
Cutting solutions upgrade
Design and product development for better cost management
Workforce Enablement
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DESIGN TO COST & MANUFACTURINGCAD and IndustrializationFrom virtual prototyping to manufacturing
Styling, Prototyping & Purchasing needs include…
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Complexity & Variability Brand & Competitiveness
Profitability Project management
Increased styles and variety
Comfort
Trim ability
Feature & technology integration
Optimized cost targets
Standardization
Brand recognition
Innovation
Competitiveness
Quick Requests for Quotation
Quick time to market
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Virtual Prototyping & Digital Product Development
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Seating & Interior Development Streamlined Digital Processes
Prototyping
Development
Design Pre-Production
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& &
Prototyping Product validation Material consumption Leather costing
Technical Specifications Quality zones Pattern Industrialization
Cut preparation Digitalization Nesting Cut execution Offloading
Production control Key performance
indicators Optimization powered by
data intelligence
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PROTOTYPING PRODUCT DEVELOPMENT MANUFACTURING OPTIMIZATION
LeatherReporting
Integrated Processes from Design to Production
3D 2D
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Reduced development time by 30% Improved Material Yield by 5-15%
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Virtual Prototyping & Simulation Applied to Trim Covers
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Digital seat cover development Traditional digital activities
Foam design(Catia, Icem Surf, NX…)
Mechanical Frame design (Catia, NX…)
STO Design(Alias, Icem Surf…)
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Benefits of Virtual Prototyping for Product Development
PROCESS IMPROVEMENTCOST SAVINGSTIME SAVINGS
Industrial cost reduction
Less physical prototypes
Lower material consumption and labor cost reduction in production
Answer RFQ in a few days
-30% to -50% sampling and development iterations
Mastering targeted costs fromaccurate preliminary costing
Efficient communication across the supply chain
No mistake on CAD data translation, pattern digitizing, BOM and documentation
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From workorder to data-driven optimizationEmpowerment for Seamless Manufacturing
HardwareConfigurations
Data-Driven ProductionDigitalization of Leather
Support & MaintenanceServices
Lectra global expertise, Consulting, performance
improvement…
Cutter
Additional equipment
Operating systems
Operating Software Pilots LeatherScan, Leather Nest, Versalis Pilot….
ApplicationModules
Connectors
Data
Leather Hides, Workorder, Production times, Cut parts
Throughput, Yield Efficiency,
LeatherImportImport Workorder from ERP, MES…
Optimize the production with LeatherReporting
LeatherExpert, LeatherSimulation ….
Operational Support Center
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Versalis Digital Leather Cutting Room
Versalis Automotive Online Workorders
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CUT PREPARATION DIGITALIZATION NESTING CUTTING OFFLOADING OPTIMIZATION
LEATHER ORDER LEATHER SCAN LEATHER NEST VERSALIS PILOT LEATHER OFFLOAD
LEATHER SUPERVISOR
LEATHER EXPERTLEATHER SIMULATION
LEATHER REPORTING
LEATHER IMPORTSoftware
Hardware
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High speed flexibility and agility through digitization to set new programs quickly
• No need for weeks of tooling development• Easily move from one program to another
High performance • 1, 2 or 3 heads with high-frequency vibration blades (20KRPM)
that can adjust to any leather and parameters
High cutting quality on unlimited number of notches or drills• very high scanning precision (+/-0,5mm)• hide analysis to ensure the right parameters for the program
Enhanced leather savings from advanced nesting software able to adapt to OEM model and material constraints
High Speed Flexibility, Precision, Performance
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Maximize Material YieldLeather, Alcantara, fabric, vinyl, foam, carbon fiber
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Digitalization Benefits the Complete Supply ChainDeliver Operational Excellence and OEE
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FLEXIBILITY MATERIAL SAVINGS TIME SAVINGS PRODUCTIVITY DATA DRIVEN
PRODUCTION QUALITY
Meet shortened production cycles
Meet increasing quality standards
with precision craftsmanship
Up to 85% optimization
of useable hide surface
Cut up to20 hides per hourwith 2 operators at
96% uptime
Leverage critical maintenance and production data through software
and services
High speed responseto model changes and
flexible production
DIGITIZED AND AUTOMATED PROCESS
TACHI-S & LECTRA
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The Challenge• Improve production workflow & flexibility • Reduce operational costs • Reduce material consumption
The Result • Equipment efficiency rose from 56% to 72% • Productivity increased from 550 to 1000 car sets per day• Tachi-S obtained a 50%, 120% and 137% improvement on three materials
“In addition to a reduction in costs per set,this project has helped us improve the quality of our products and delivery times in the development of new platforms required by our customers.”Luis SoriaSenior Corporate Purchasing ManagerTachi-S Mexico
(Now President, Tachi-S Brazil)
UPCOMING EVENT – OCTOBER 2019
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Visit our 30’ booth at The Suburban Collection, featuring Tachi-S, Lectra & Durkopp AdlerNovi MIOctober 22-24
For more informationMark ThomsonNorth America Marketing Manager, Automotive
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JimCOLLINSVP [email protected]
Thank you!
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GraemeStewart
Sr Director, [email protected]
