Gruppo Mastrotto expands its digital leather-cutting footprint alongside OEMs worldwide
Customer Company Size
Large Corporate
Region
- Europe
- America
- Asia
Country
- Italy
- Brazil
- Indonesia
- Mexico
Product
- Versalis
Tech Stack
- Industry 4.0
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Productivity Improvements
- Cost Savings
- Customer Satisfaction
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
About The 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.
The 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.
The 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.
Operational Impact
Quantitative Benefit
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