Lectra Case Studies Gruppo Mastrotto expands its digital leather-cutting footprint alongside OEMs worldwide

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	Gruppo Mastrotto expands its digital leather-cutting footprint alongside OEMs worldwide Lectra

Gruppo Mastrotto expands its digital leather-cutting footprint alongside OEMs worldwide

Lectra

Technology Category	Functional Applications - Manufacturing Execution Systems (MES) Functional Applications - Product Lifecycle Management Systems (PLM) Functional Applications - Remote Monitoring & Control Systems
Applicable Industries	Automotive
Applicable Functions	Discrete Manufacturing Product Research & Development Quality Assurance
Use Cases	Manufacturing System Automation Predictive Maintenance Process Control & Optimization
Services	System Integration Software Design & Engineering Services Training
Challenge	Gruppo Mastrotto’s automotive business unit needed to enhance its manufacturing flexibility to meet evolving customer requirements brought about by rapidly changing consumer expectations. The tannery sought to optimize workflow and processes at its high-intensity automotive manufacturing plants, located on three different continents. The company faced the challenge of handling a high number of engineering changes associated with program changeovers, which required quick and seamless pattern development directly from digital files to eliminate costly retooling that could take several months. Read More
About Customer	Headquartered in Arzignano, Italy—Europe’s largest leather tanning district—family-owned and -operated Gruppo Mastrotto produces more than 21 million m2 of high-quality bovine leathers annually for the garment, footwear, leather goods, furniture, marine seating, and aviation industries. With consolidated turnover of €460 million and a worldwide workforce of 2,400, the company runs operations at 20 manufacturing and logistics plants in Italy, Brazil, Indonesia, Mexico, and Tunisia. Gruppo Mastrotto’s automotive business unit, run as a standalone entity since 2009, continues to undergo rapid expansion to become more responsive to vehicle manufacturers. Read More
Solution	To modernize Gruppo Mastrotto’s cutting rooms, a decision was made to adopt the Versalis digital leather-cutting solution in 2014. Following a series of benchmark tests, Lectra was chosen as the partner to help raise the skill level in the automotive cutting room. Implementation of the advanced leather-cutting solution Versalis has enabled flexible automated cutting as well as optimized material usage, even for the most complex designs. The new, digitalized model of leather-cutting efficiency is currently being applied to sites in Mexico and Tunisia. Lectra’s best-in-class technology, unique business expertise, and worldwide capabilities enable the company to support Gruppo Mastrotto on all of the international markets where it operates, helping the tannery to achieve its continuous improvement goals and fulfill its ambitious expansion strategy. Read More Log in to view content
Contents

Technology Category

Functional Applications - Manufacturing Execution Systems (MES)

Functional Applications - Product Lifecycle Management Systems (PLM)

Functional Applications - Remote Monitoring & Control Systems

Applicable Industries

Automotive

Applicable Functions

Discrete Manufacturing

Product Research & Development

Quality Assurance

Use Cases

Manufacturing System Automation

Predictive Maintenance

Process Control & Optimization

Services

System Integration

Software Design & Engineering Services

Training

Challenge

Gruppo Mastrotto’s automotive business unit needed to enhance its manufacturing flexibility to meet evolving customer requirements brought about by rapidly changing consumer expectations. The tannery sought to optimize workflow and processes at its high-intensity automotive manufacturing plants, located on three different continents. The company faced the challenge of handling a high number of engineering changes associated with program changeovers, which required quick and seamless pattern development directly from digital files to eliminate costly retooling that could take several months.

About Customer

Headquartered in Arzignano, Italy—Europe’s largest leather tanning district—family-owned and -operated Gruppo Mastrotto produces more than 21 million m2 of high-quality bovine leathers annually for the garment, footwear, leather goods, furniture, marine seating, and aviation industries. With consolidated turnover of €460 million and a worldwide workforce of 2,400, the company runs operations at 20 manufacturing and logistics plants in Italy, Brazil, Indonesia, Mexico, and Tunisia. Gruppo Mastrotto’s automotive business unit, run as a standalone entity since 2009, continues to undergo rapid expansion to become more responsive to vehicle manufacturers.

Solution

To modernize Gruppo Mastrotto’s cutting rooms, a decision was made to adopt the Versalis digital leather-cutting solution in 2014. Following a series of benchmark tests, Lectra was chosen as the partner to help raise the skill level in the automotive cutting room. Implementation of the advanced leather-cutting solution Versalis has enabled flexible automated cutting as well as optimized material usage, even for the most complex designs. The new, digitalized model of leather-cutting efficiency is currently being applied to sites in Mexico and Tunisia. Lectra’s best-in-class technology, unique business expertise, and worldwide capabilities enable the company to support Gruppo Mastrotto on all of the international markets where it operates, helping the tannery to achieve its continuous improvement goals and fulfill its ambitious expansion strategy.

Impact #1	The high number of engineering changes associated with program changeovers can now be handled quickly and seamlessly by developing patterns directly from digital files.
Impact #2	The increased productivity and improved material usage of its modernized cutting rooms enable the company to stay apace of continually evolving customer requirements.
Impact #3	The advantages of digital leather cutting include improved productivity, improved efficiency in terms of the use of raw materials and leather, and greater flexibility to respond to customer requirements.

Impact #1

The high number of engineering changes associated with program changeovers can now be handled quickly and seamlessly by developing patterns directly from digital files.

Impact #2

The increased productivity and improved material usage of its modernized cutting rooms enable the company to stay apace of continually evolving customer requirements.

Impact #3

The advantages of digital leather cutting include improved productivity, improved efficiency in terms of the use of raw materials and leather, and greater flexibility to respond to customer requirements.

Benefit #1	Gruppo Mastrotto produces more than 21 million m2 of high-quality bovine leathers annually.
Benefit #2	The company has a consolidated turnover of €460 million.
Benefit #3	Gruppo Mastrotto has a worldwide workforce of 2,400 employees.

Benefit #1

Gruppo Mastrotto produces more than 21 million m2 of high-quality bovine leathers annually.

Benefit #2

The company has a consolidated turnover of €460 million.

Benefit #3

Gruppo Mastrotto has a worldwide workforce of 2,400 employees.

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Overview

Gruppo Mastrotto expands its digital leather-cutting footprint alongside OEMs worldwide

Operational Impact

Quantitative Benefit