Lectra > Case Studies > Guangzan fuels rapid growth with leaner operations and increased productivity

Guangzan fuels rapid growth with leaner operations and increased productivity

Customer Company Size

Mid-size Company

Region

Asia

Country

China

Product

DesignConcept 2D
Diamino
VectorAuto iX6

Tech Stack

CAD/CAM
Prototyping Software
Marker-Making Solution

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Productivity Improvements
Cost Savings
Waste Reduction

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

Quality Assurance

Use Cases

Manufacturing System Automation
Predictive Maintenance
Process Control & Optimization

Services

System Integration
Software Design & Engineering Services
Training

About The Customer

Based in Shanghai, China, Guangzan is a supplier of automotive headrests and interior trim. Initially an automotive injection molding manufacturer, the company expanded into automotive seating trim covers, from the cutting of fabric parts to sewing and assembly. Founded in 1994, Guangzan has a production plant in Shanghai and employs a workforce of over 200. The company upgraded its product line to attract more customers and grow its business. However, new revenue opportunities also brought challenges to productivity and cost control, affecting the company's overall growth.

The Challenge

New revenue opportunities brought challenges to productivity and cost control, hindering Guangzan's overall growth. The company found it difficult to meet demand with inflexible production capabilities based mainly on manual die press operations. Increasingly sophisticated seating designs involving smaller, more intricate parts added further manufacturing complexity. Guangzan's business underwent a major transformation after signing a contract with an OEM, leading to a company-wide initiative to streamline production. Guangzan sought a digital cutting solution to provide higher production capacity while ensuring premium quality.

The Solution

At the end of 2015, Guangzan acquired two automotive fabric cutters from a rival CAD/CAM system manufacturer. However, the equipment was not suited to cutting the multi-fabric material used in headrests, leading to technical limitations and material waste. Determined to build a foundation for long-term growth, Guangzan began researching alternative fabric-cutting solutions. With the support of Lectra’s Professional Services, Guangzan re-outfitted its cutting line with DesignConcept 2D prototyping software, Diamino marker-making solution, and VectorAuto iX6 precision fabric cutting equipment. Lectra’s Vector iX6 features a 2x7 mm blade that exerts less pressure on synthetic materials, minimizing friction and the risk of fusion. Combined with Vector iX6’s more sensitive stress sensor, the precision blade enables a reduction of buffer between pieces, significantly lowering the waste ratio. Together with Lectra’s automatic nesting solution, Vector iX6 enables the best possible placement of pieces, saving time and maximizing fabric efficiency.

Operational Impact

Lectra’s integrated solution comprising advanced software, cutting equipment, and value-added professional services has enabled Guangzan to significantly optimize production.
Overall productivity per machine has improved, and the lower waste ratio and superior cut quality of the Vector digital cutting solution have increased productivity by more than 50%.
The precision blade of Vector iX6 minimizes friction and the risk of fusion, reducing the buffer between pieces and significantly lowering the waste ratio.
Lectra’s automatic nesting solution enables the best possible placement of pieces, saving time and maximizing fabric efficiency.
Guangzan has succeeded in increasing productivity by more than 50% by lowering the waste ratio and drastically improving the quality of cut parts for the automotive trim covers it supplies to major carmakers.

Quantitative Benefit