Lectra Case Studies Tachi-S Mexico Fulfills Growth Potential with Lectra

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	Tachi-S Mexico Fulfills Growth Potential with Lectra Lectra

Tachi-S Mexico Fulfills Growth Potential with Lectra

Lectra

Technology Category	Analytics & Modeling - Predictive Analytics Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Automotive
Applicable Functions	Process Manufacturing Quality Assurance
Use Cases	Manufacturing System Automation Predictive Maintenance Process Control & Optimization
Services	System Integration Training
Challenge	Tachi-S Mexico faced significant challenges in their cutting room, including low efficiency, high fabric consumption, and quality issues. These problems hindered their ability to meet the growing demand from car makers opening plants in Mexico. The company was looking to improve production capacity, reduce operational costs, and minimize quality defects to capitalize on the expected growth. They initially considered acquiring new cutting equipment but were advised by Lectra experts to perform in-depth analyses of their current production processes to identify areas for improvement. Read More
About Customer	Tachi-S is a leading automotive seating supplier with a 50-year history of creating inspirational products. The company works with major automakers as an independent seat maker, delivering 2.4 million seats to the global market each year. Tachi-S aims to provide an inspiring experience for its customers through its high-quality seats, which are becoming increasingly important as a key element in the presentation of a car. The company operates globally and has a strong presence in Mexico, where it has been experiencing significant growth due to the influx of car makers opening plants in the region. Read More
Solution	Lectra partnered with Tachi-S Mexico to optimize their cutting processes without the need for additional equipment. Leveraging their expertise in the cutting process and experience in advising automotive companies, Lectra conducted a customized consulting project. They applied lean principles and used assessment methods such as DILO (Day in the Life Of) studies, Value Stream Mapping, and analysis of overall equipment efficiency to identify and eliminate non-value-added activities. This approach enabled Tachi-S Mexico to increase production capacity, improve product quality, and reduce operational costs. The project was divided into three phases, with the first two phases already completed, yielding impressive results. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Automotive

Applicable Functions

Process Manufacturing

Quality Assurance

Use Cases

Manufacturing System Automation

Predictive Maintenance

Process Control & Optimization

Services

System Integration

Training

Challenge

Tachi-S Mexico faced significant challenges in their cutting room, including low efficiency, high fabric consumption, and quality issues. These problems hindered their ability to meet the growing demand from car makers opening plants in Mexico. The company was looking to improve production capacity, reduce operational costs, and minimize quality defects to capitalize on the expected growth. They initially considered acquiring new cutting equipment but were advised by Lectra experts to perform in-depth analyses of their current production processes to identify areas for improvement.

About Customer

Tachi-S is a leading automotive seating supplier with a 50-year history of creating inspirational products. The company works with major automakers as an independent seat maker, delivering 2.4 million seats to the global market each year. Tachi-S aims to provide an inspiring experience for its customers through its high-quality seats, which are becoming increasingly important as a key element in the presentation of a car. The company operates globally and has a strong presence in Mexico, where it has been experiencing significant growth due to the influx of car makers opening plants in the region.

Solution

Lectra partnered with Tachi-S Mexico to optimize their cutting processes without the need for additional equipment. Leveraging their expertise in the cutting process and experience in advising automotive companies, Lectra conducted a customized consulting project. They applied lean principles and used assessment methods such as DILO (Day in the Life Of) studies, Value Stream Mapping, and analysis of overall equipment efficiency to identify and eliminate non-value-added activities. This approach enabled Tachi-S Mexico to increase production capacity, improve product quality, and reduce operational costs. The project was divided into three phases, with the first two phases already completed, yielding impressive results.

Impact #1	After the first phase, Tachi-S Mexico gained a better understanding of parameters, spreading methods, preventive maintenance routines, and operational best practices.
Impact #2	The company was able to produce 275 more car seat sets per day and increase equipment efficiency by 16%.
Impact #3	Lectra's consultants demonstrated the importance of accurately evaluating and following quality, availability, and performance ratios using Overall Equipment Effectiveness data.

Impact #1

After the first phase, Tachi-S Mexico gained a better understanding of parameters, spreading methods, preventive maintenance routines, and operational best practices.

Impact #2

The company was able to produce 275 more car seat sets per day and increase equipment efficiency by 16%.

Impact #3

Lectra's consultants demonstrated the importance of accurately evaluating and following quality, availability, and performance ratios using Overall Equipment Effectiveness data.

Benefit #1	Production volumes increased from 550 to 1,000 car seat sets per day.
Benefit #2	Equipment efficiency rose from 56% to 72%.
Benefit #3	Cost per car seat set was reduced by $0.38.

Benefit #1

Production volumes increased from 550 to 1,000 car seat sets per day.

Benefit #2

Equipment efficiency rose from 56% to 72%.

Benefit #3

Cost per car seat set was reduced by $0.38.

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Overview

Tachi-S Mexico Fulfills Growth Potential with Lectra

Operational Impact

Quantitative Benefit