From the Sector

The Industry of the Future Alliance (AIF) has awarded Lectra with their ‘Showcase for the Industry of the Future’ label for demonstrating the criteria exemplarity, innovation and commitment. This certification is given to companies who have concretely developed a ground-breaking project to organize their production by leveraging the potential of digital.

The AIF bestowed Lectra with this distinction for its competitiveness concerning cost, quality and delivery times, all obtained thanks to a lean approach and reflection around the design of its products. Further, Lectra received the certification for its competitiveness regarding value, achieved thanks to mastering customer use from which new associated services have flowed. Since 2013, Lectra has invested €86 million in R&D, representing 9.4% of its revenues. This Investment has enabled Lectra to undergo a metamorphosis—based on methodological advances and fundamental technologies—increasing recruitment and growing competitiveness in all of its markets and geographical sectors.

With ten years’ experience in the industrial internet of things for cutting and expertise in software Solutions to automate and optimize design and product development, Lectra is in an unrivalled position to Support customers as they enter the ‘industry of the future’ era.

Pressure from certain shareholders to relocate manufacturing to China in 2005, triggered Lectra’s industrial project. Following risk analyses—the cost of transport for the European market, the turnover in qualified labor, uncertainty over patent rights and quality—Lectra decided to keep manufacturing in France. This choice was conditional on: disruptive innovation; upgrading; increased value to customers; and a rise in productivity.

The project was accompanied by a well-structured lean approach and organizational changes, which enabled Lectra to achieve the desired level of excellence in terms of productivity and competitiveness.

Some of the changes that took place thanks to this project are as follows: Growth in industrial performance due to an improvement in working conditions, with teams involved in the lean approach; Production engineers involved in creating awareness around factory constraints for a new offer as early as the design process. This co-design product/process optimizes global costs; Emphasis on product, process and logistics’ modularity with the latest possible integration of options (delayed differentiation). This enables logistics’ constraints to be taken into account as early as the engineering phase. Product modularity allows, for example, machines to be put in containers when they might otherwise require special heavy-goods transport.

Lectra’s factory improved its productivity rate by 18 points in three years, and has since maintained it at 89%. Costs have already reduced by 25% and the quality and level of service has improved. In terms of positioning, Lectra has confirmed its leadership in the high-end segment. Lectra has enriched its offer with end-to-end services and innovative, connected products whose embedded intelligence offers Smart Services, notably for predictive maintenance.

Lectra has leveraged more than 10 years of experience in connected manufacturing to offer Versalis®, an innovative digital solution designed to cut leather without compromise on quality. Featuring a powerful automatic nesting system for overall improvements in efficiency, the fully automated solution enables automotive leather suppliers to cut costs, improve productivity and minimize waste while also establishing a pathway to value-added Industry 4.0 processes.

Currently, almost 90% of leather used for automotive applications is cut using manual die presses, which require designers to build a physical prototype and finalize the design through trial and error. Lectra offers a fully digitalized leather solution from prototyping to cut parts—when used in combination with Lectra’s 3D prototyping and pattern-making software, Versalis digital leather cutting solution enables a 12-16 week reduction in development and launch cycles for vehicle seating models.
During the leather-cutting phase, the latest release of Versalis LeatherSuite allows automotive leather suppliers to achieve up to 15% greater productivity. Lectra’s end-to-end automotive leather offering furthermore guarantees optimal uptime through an extensive worldwide support network of field engineers and technical experts.
"Lectra focuses on a consultative approach that allows it to fully understand the customer’s needs before building a solution comprising software, hardware, consulting, training, and after-sales support,” said Frost & Sullivan Industry Analyst Kamalesh Mohanarangam. "Lectra’s equipment is fitted with more than 200 sensors that predict failure and immediately report issues to its call centres. This product feature and service has resulted in 98% uptime and very fast mean time to repair."

Although digital leather cutting solutions are an investment, leather cutters and Tier-1 suppliers have begun to recognize the value of these products. On average, Lectra’s solutions help customers achieve up to 7% savings on leather compared to manual die-press methods by minimizing human error and variability in the cutting room. A benchmark test of leather trim cutting for door panels demonstrated a 3.5% gain in material made possible by Versalis’ superior nesting capabilities compared to the customer’s yield using manual nesting with die press machines, representing potential savings of €9 million per year.
Versalis is the fruit of significant R&D investment for the company, which has always made re-investment of capital a priority. As part of a transformational plan, Lectra spent more than €50 million in investments between 2011 and 2015. With Lectra’s new strategy focusing on supporting their customers’ transition to Industry 4.0 standards, Lectra will increase the share of revenues dedicated to R&D to 10% for the period from 2017 to 2019, representing a rise of about 50% between 2016 and 2019.

With digitalization transforming the way consumers shop, today’s fashion companies are playing a neverending game of catch-up, as they compete for the attention of a generation of connected, fickle-minded millennials who want it all: personalization, sustainability, quality and speed, accessible at all times, across multiple channels, and at the lowest price. Industry 4.0 is not only revolutionizing how manufacturers operate, but also how brands and retailers need to function, if they want to be fast and agile enough to meet the needs of this demanding new consumer. The stakes are high and how effectively companies harness technology to put the consumer at the heart of their process will be the deciding factor in who comes out ahead and who gets left behind.

Lectra Fashion PLM 4.0 has undergone a drastic reboot to give fashion and apparel companies the speed and agility they need to tackle the challenges of Industry 4.0 head on. Lectra Fashion PLM 4.0, with the widest functional scope on the market, acts as an intelligent nerve center to the digital supply chain, from planning through design to production. This ensures a consistent flow of error-free data between processes, technologies and people. The system connects CAD, industry-standard software such as Adobe Illustrator, company IT systems (such as ERP) and external suppliers, so that actors across the supply chain can work on, save and share information on the platform, ensuring data integrity.
The solution also draws on best practices, fashion-business intelligence and real-world scenarios to automate administrative and repetitive tasks, with templates, standard libraries and shortcuts that allows more time for value-added activities. The final result is a fast, connected digital supply chain that helps fashion companies jump on trends quickly and deliver products that fulfill their customer’s expectations.

  The new cutting room will expand the German car parts maker’s airbag cutting capacity in Europe. This latest collaboration between Lectra and its longtime customer builds on a mutual relationship of trust reaching back to previous ZF TRW projects in Portugal, Poland, Mexico and China. Having recently devised a worldwide airbag growth strategy, the company turned once more to Lectra to help reinforce the capacity of its European manufacturing base.
Early in 2016, Lectra unveiled the revolutionary FocusQuantum range, leading to certification of the integrated airbag cutting solution by the customer’s cutting room managers across the globe. Later that year, ZF TRW also certified Lectra’s FocusQuantum Suite cutting preparation software. The stringent process carried out by ZF TRW bore out the productivity, performance and quality of the state-of-the-art airbag cutting solution and advanced software system.

“By evaluating the solution in accordance with established practices, we were able to confirm that FocusQuantum will help satisfy the projected output of our newest facility,” notes Victor Seoane, head of Global Manufacturing Engineering for Inflatable Restraint Systems, ZF TRW. "We were impressed by the innovation that Lectra’s FocusQuantum offers, enabling us to significantly reduce our cutting cost per bag."
“With this new collaboration, Lectra demonstrates yet again the added value built into the integrated design of FocusQuantum,” states Céline Choussy Bedouet, Chief Marketing and Communications Officer, Lectra. "The acquisition of two FocusQuantum will enable ZF TRW to meet short-term productivity objectives while also laying the foundation for future growth.”