It is understood that when the seat interior is cut, each 1 mm reduction in the gap between the pieces is equivalent to saving about 1% of the fabric. For automotive suppliers, this means saving millions of yuan in fabric costs each year.
Under the decline of the auto market and the pressure of competition, every small cost saving is important for car companies and suppliers …
Previously, in terms of cost reduction and efficiency enhancement of car seat interiors, they mostly appeared in light weight or raw material savings. In fact, in many "hidden" processes, the cost reduction was even as fine as "millimeter level". Today we will talk This cutting process is the latest example. It is understood that when cutting, the gap between the pieces is reduced by 1 mm, which is equivalent to saving about 1% of the fabric. For automotive suppliers, this means saving millions of yuan in fabric costs each year.
How is the "millimeter level" cost reduction achieved?
According to reports, in general, there is a gap of 2 mm to 5 mm in the cutting of car seat interior fabrics, which means that a large amount of fabric will be wasted. In order to further reduce costs, the seat interior supplier has put forward the idea of 'zero clearance' and requested that product quality be guaranteed simultaneously. It is worth mentioning that, in terms of cutting, the gap between the pieces is reduced from 2 mm to zero clearance, which is completely incomparable compared with the reduction from 4 mm to 2 mm. It is very difficult, like an excellent marathon. Players, even if they only improve their performance by one second, they need to make great efforts behind them. Therefore, this has also become a "pain point" for seat interior suppliers.
A few years ago, Lectra, the innovation leader in the field of digital cutting, decided to take this "hard bone" and invest a large amount of human and financial resources in related research and development. Finally, after multiple tests and field verification of the customer factory, a "zero gap" The solution was presented on its VectorAutomotive iP6 & iP9 devices.
"The whole development process is very complicated, because it is a soft fabric with many layers, and at the same time, it must ensure that the cutting must reach 100% accuracy at any time, which poses a great challenge to the entire technology. Fortunately, The thing is, in the end, we succeeded, so we call it a 'breakthrough.' 'Javier Garcia, president of Lectra's Asia Pacific region, said in an interview with Gasgoo.
At the recent CISMA2019 exhibition, Lectra crossed the ocean and shipped this "heavyweight" equipment that can achieve zero-gap cutting to the scene. This is also the world's first appearance of this latest fabric cutting solution, which has caused many industry Stops and inquiries for professionals and exhibitors.
Regarding how to achieve "zero gap" in equipment, the relevant person in charge of Lectra pointed out that there are three main technical supports:
1) Advanced high-precision conveyor belt combined with the new image sensor technology, which can detect pressure and
When adjusting the crop parameters.
2) Built-in blade management system ensures high-precision cutting. The system includes the VectorAutomotive iP6 & iP9 Pilot and an additional feature. A powerful algorithm can manage common lines in real time to ensure the highest degree of accuracy.
3) Specially designed cutter head can cut multi-layer synthetic fabrics and foam backing fabrics.
Car interior trim, car interior trim, Lectra
It is understood that during the exhibition, Lectra also launched a Dashboard Kanban service for the entire range of cutting equipment, which can track the performance and operation of the equipment throughout the process, and view the real-time cutting situation and cutting efficiency of the cutting room in order to minimize fabric Consumption, reduce downtime due to machine failure, and maintain the best performance of the machine at all times. At the same time, the Dashboard Kanban service can also obtain valuable key production indicators, quickly identify areas that need improvement, and help decision-makers quickly overview production efficiency and make corresponding decisions.
It is worth mentioning that the new solutions are based on Lectra 4.0 strategy to realize the digitalization and intelligence of the entire process. According to reports, related equipment has the ability to access the cloud. Lectra plans to launch new cloud-based controls next year. In the fashion and home industries, related digital solutions launched by Lectra have been based on cloud technology and can automatically process orders. In addition, the Dashboard Kanban service has realized rapid access to device production data through the cloud, such as KPIs.
What about market feedback?
"For automakers, the new solution has definitely not sacrificed quality when it helped them save costs. At the same time, it can help them reduce the time to market and delivery of products. Therefore, after the launch of the product, it has received a lot of attention. Currently, Orders have been received. "Said Frederic Gaillard, vice president of Lectra's tailored product marketing.
However, because zero-gap solutions are more difficult to implement, it is understood that before the introduction of VectorAutomotive iP6 & iP9, it was also questioned. "However, many customers expressed surprise and shock when they saw the demonstrations in person. Asked when we can bring their own fabrics and products to our technical center for on-site testing." Frederic Gaillard said, "We There is an international technology center in Shanghai that can help customers conduct in-depth testing of products. At the same time, we will also go to customers to understand their specific production, operating procedures and steps, and provide targeted solutions to help them solve problems. In general, customers will accept this solution after seeing the difference in parameters before and after using the new technology and the tangible benefits. "
Changes in the new market situation
In recent years, with the rapid development of new technologies such as intelligence, interconnection, and electrification, as well as increasing consumer diversification and personalized needs, the Chinese auto market has ushered in a new period of profound transformation. In addition, the market is gradually becoming more rational and the downward trend is obvious. Under this situation, the entire automotive industry chain has undergone relevant adjustments to meet the changes and challenges that are coming.
Regarding the development of the Chinese auto market, Javier Garcia pointed out that the automotive industry is a cyclical industry with peaks and valleys. However, China's situation is quite special, because it has maintained rapid growth for the past 30 years, and the current slowdown is actually returning to the normalization of the industry. "When sales decline, suppliers will improve or improve related production processes and processes, and adopt more effective technologies to reduce costs. This is an opportunity for Lectra. Our digital solutions can make They quickly get a return on their investment, and the increase in efficiency and cost savings in the production process can soon cover or supplement the costs they pay for their equipment. "
In addition, with the increase of consumer individual demand, many car companies have begun to consider product customization to give car owners more choices and enhance market competitiveness. The interior is naturally the most obvious part of a car, such as the diversity of colors and the matching of fabrics. To achieve mass production of customized products, digital or intelligent production is an inevitable choice.
Digital solutions have always been the key to Lectra's role as a leader in car seat interiors. It is understood that Lectra's market share in the field of car interior trimming has reached approximately 70%.
Javier Garcia said: "In the future, the market will be highly intelligent and digital, and intelligent manufacturing is the general trend. Our customers are in the process of deepening their business in order to seize new opportunities in the market. We are experiencing a real digital Revolution. This will change the way products are designed, developed and manufactured. In order to meet customer needs and support their business transformation, we are deploying Lectra 4.0 strategy to provide new revolutionary solutions. With data analysis and mining technology, we provide intelligence And network equipment, and continuously optimize the integration between equipment, software and services. Help customers to continuously improve processes and achieve cross-region deployment to ensure competitiveness and win consumers. "