Tesca accelerates production innovation with 4.0 solutions

In 2022, Tesca invested in Automotive Cutting Room 4.0, combining best-in-class equipment with advanced, data-driven software. 

Vector Automotive iP is the first fabric-cutting solution to merge breakthrough cutting technology with sophisticated software for reduced buffer-cutting, delivering exceptional precision and material optimization—even for complex, high-end projects. 

Algopex complements this by providing real-time data visibility, KPI tracking, and actionable insights, maximizing equipment performance and ensuring consistency across all sites. 

This strategic move is designed to boost efficiency, optimize material usage, and enhance visibility across the company’s global production network, enabling it to meet the exacting standards of premium carmakers and drive continuous innovation.

The integration of Vector Automotive iP and Algopex has addressed inefficiencies in cutting room performance and quality. Key benefits include:

• 3.5% reduction in raw material consumption
• +2% increase in cutting capacity
• Standardized reporting and KPIs across dozens of sites and more than 10 production facilities
• Minimized downtime through real-time performance monitoring

Operators can now visualize performance in real time, minimize downtime, identify inefficiencies, and implement corrective actions. The result is boosted cutting capacity, optimized material usage, and consistent quality. Vector Automotive iP further enhances efficiency with reduced buffer sizes, long-life consumables, and lower maintenance costs, delivering a 1% material gain for every 1mm buffer reduction. 

With support from Lectra’s Customer Success Team, Tesca leveraged Algopex to benchmark performance across its global sites, manage peak activity, and track KPIs. 

This collaborative approach revealed underperforming equipment, highlighted inefficiencies, and guided improvements in operator practices and machine settings, driving continuous improvement throughout the organization. 

Tesca plans to expand its use of data analytics and pursue ongoing improvement to further advance sustainability and efficiency goals. 
By leveraging the full potential of each piece of equipment, Algopex will continue to boost cutting-room performance, while Vector Automotive iP remains at the core of operations, delivering precision and minimizing waste and costs. 
Together, these solutions will drive Tesca digital transformation, operational excellence, and commitment to innovation.

With Algopex we can in real time monitor each plant and react if any issues are encountered, limiting stoppage and interruptions. We can in an instant know the performance of each line on each plant simply using a mobile phone.

Alexandra Oliveira, Innovation Leader for Cut and Sew and Leather Manager, Tesca