Lectra Case Studies ECA Moves Up the Leather Value Chain with Zero-Buffer Cutting

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	ECA Moves Up the Leather Value Chain with Zero-Buffer Cutting Lectra

ECA Moves Up the Leather Value Chain with Zero-Buffer Cutting

Lectra

Technology Category	Functional Applications - Manufacturing Execution Systems (MES) Functional Applications - Product Lifecycle Management Systems (PLM)
Applicable Industries	Automotive Consumer Goods
Applicable Functions	Process Manufacturing Quality Assurance
Use Cases	Predictive Maintenance Manufacturing System Automation Factory Operations Visibility & Intelligence
Services	System Integration Training Software Design & Engineering Services
Challenge	ECA, a Belgian automotive supplier, faced the challenge of increasing their yield of leather cut parts while reducing labor. The surge in demand for leather interiors in vehicles made it critical for ECA to meet changing consumer preferences quickly. The traditional die cutting process was labor-intensive and inflexible, requiring different cutting knives for each car model. This process also incurred high OEM tooling costs and long start-up times, making it difficult for ECA to remain competitive in a rapidly evolving supply chain. Read More
About Customer	Founded in 1981, ECA NV is a family-run firm located in Assenede, Belgium. The company specializes in aftermarket vehicle upholstery, particularly leather, and the manufacturing of car mats for OEMs. ECA employs 130 people and is part of the ECA Group, which includes Berco, I M Kelly, and Tiscotex NV. Over the years, ECA has built a reputation for quality and innovation in the automotive aftermarket industry. The company has been a customer of Lectra since 2006, leveraging their expertise to transition from manual to automated leather cutting processes. Read More
Solution	To address these challenges, ECA turned to Lectra's Versalis® leather cutting solution. This automated system significantly optimized material usage and reduced manpower requirements. The Versalis system enabled ECA to implement automatic nesting, allowing for zero-buffer cutting and improving hide efficiency. The switch from die cutting to automation reduced start-up times and eliminated OEM tooling costs. Over five years, ECA continued to upgrade its installed base with Lectra's leather- and textile-cutting solutions and prototyping software. Benchmark tests at Lectra's R&D center in Bordeaux convinced ECA of the exceptional performance of VersalisAuto, leading to material savings of 10% compared to their previous solution. Read More Log in to view content
Contents

Technology Category

Functional Applications - Manufacturing Execution Systems (MES)

Functional Applications - Product Lifecycle Management Systems (PLM)

Applicable Industries

Automotive

Consumer Goods

Applicable Functions

Process Manufacturing

Quality Assurance

Use Cases

Predictive Maintenance

Manufacturing System Automation

Factory Operations Visibility & Intelligence

Services

System Integration

Training

Software Design & Engineering Services

Challenge

ECA, a Belgian automotive supplier, faced the challenge of increasing their yield of leather cut parts while reducing labor. The surge in demand for leather interiors in vehicles made it critical for ECA to meet changing consumer preferences quickly. The traditional die cutting process was labor-intensive and inflexible, requiring different cutting knives for each car model. This process also incurred high OEM tooling costs and long start-up times, making it difficult for ECA to remain competitive in a rapidly evolving supply chain.

About Customer

Founded in 1981, ECA NV is a family-run firm located in Assenede, Belgium. The company specializes in aftermarket vehicle upholstery, particularly leather, and the manufacturing of car mats for OEMs. ECA employs 130 people and is part of the ECA Group, which includes Berco, I M Kelly, and Tiscotex NV. Over the years, ECA has built a reputation for quality and innovation in the automotive aftermarket industry. The company has been a customer of Lectra since 2006, leveraging their expertise to transition from manual to automated leather cutting processes.

Solution

To address these challenges, ECA turned to Lectra's Versalis® leather cutting solution. This automated system significantly optimized material usage and reduced manpower requirements. The Versalis system enabled ECA to implement automatic nesting, allowing for zero-buffer cutting and improving hide efficiency. The switch from die cutting to automation reduced start-up times and eliminated OEM tooling costs. Over five years, ECA continued to upgrade its installed base with Lectra's leather- and textile-cutting solutions and prototyping software. Benchmark tests at Lectra's R&D center in Bordeaux convinced ECA of the exceptional performance of VersalisAuto, leading to material savings of 10% compared to their previous solution.

Impact #1	ECA achieved hide efficiency of up to 80% with the Versalis system.
Impact #2	The automated cutting system allowed for higher output with the same personnel, moving ECA from labor-intensive to technology-intensive processes.
Impact #3	Lectra's value-added Professional Services and cutting-room expertise further enhanced ECA's operational efficiency.

Impact #1

ECA achieved hide efficiency of up to 80% with the Versalis system.

Impact #2

The automated cutting system allowed for higher output with the same personnel, moving ECA from labor-intensive to technology-intensive processes.

Impact #3

Lectra's value-added Professional Services and cutting-room expertise further enhanced ECA's operational efficiency.

Benefit #1	Material savings of 10% compared to the previous Lectra solution.
Benefit #2	Hide efficiency increased from 60% to 70%-80%.

Benefit #1

Material savings of 10% compared to the previous Lectra solution.

Benefit #2

Hide efficiency increased from 60% to 70%-80%.

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Overview

ECA Moves Up the Leather Value Chain with Zero-Buffer Cutting

Operational Impact

Quantitative Benefit