Maximize leather savings in automotive cutting room

The importance of leather in car seats and interiors 

Leather has long been a mark of luxury and quality in automotive interiors thanks to its durability, comfort, and sleek appearance, which have made it a favored choice among manufacturers and consumers alike. However, leather is not just about the look and feel; it's also about the judicious use of resources. Efficient leather cutting is crucial for reducing waste and maximizing savings without compromising on quality. 

Why saving leather and optimizing hides matter 

In an era where sustainability is as important as profitability, saving leather has become a priority for car manufacturers. Leather requires a significant investment, not just in monetary terms, but also in the resources needed for its production. Hence, making the most of every hide is essential for cost-effective manufacturing and responsible resource management. Versalis is designed for just that. The system allows manufacturers to increase nesting efficiency by up to 7% compared to die press and to cut accurately with a 00mm buffer. 

Strategies for leather material savings 

To boost material savings in the automotive cutting room, several strategies can be implemented. These focus on optimizing the cutting process, reducing waste, and ensuring that every piece of leather is utilized to its full potential. Leveraging Lectra's Versalis solution, with its advanced integrated cutting and marking equipment, can significantly enhance these efforts by streamlining processes, controlling costs, and increasing yield efficiency. 
 

1. Advanced nesting software 

Using advanced nesting software is like playing a game of Tetris, but with higher stakes. These sophisticated programs can calculate the most efficient way to lay out patterns on a hide, ensuring minimal waste. This optimization can lead to significant material savings over time. 

2. High-quality digital scanning 

Before cutting, digital scanning can detect imperfections in the leather, such as scars or branding marks. By identifying these flaws early, cutters can work around them, ensuring only the best parts of the hide are used for premium automotive interiors 

3. Regular maintenance and calibration 

To keep cutting machines performing at their best, regular maintenance and calibration are non-negotiable. Dull blades or misaligned machinery can lead to wasted material due to improper cuts or the need for do-overs. 

4. Operators training 

Even with the best technology, the human factor is critical. Skilled workers who know how to operate machines correctly and understand the importance of material savings can make a substantial difference in reducing waste. 

The role of technology for sales success 

Technology plays a pivotal role in the leather cutting process, offering opportunities for improved accuracy, speed, and savings. 

Data analysis for continuous improvement 

By analyzing cutting room data, manufacturers can identify trends and areas for improvement. This ongoing process helps refine cutting operations, leading to better material utilization and cost savings over time. Versalis, with over 250 embedded sensors for real-time process and cost control, can be leveraged to provide data intelligence to monitor and optimize overall leather cutting operations. Additionally, Versalis system interfaces guarantee seamless integration into your IT environment, ensuring a smooth and efficient workflow 

Challenges in leather cutting 

Despite best efforts, challenges in the leather cutting process are inevitable. Addressing these challenges can lead to further savings and improvements.  

With Versalis, you can collect data at every step from marking to cutting in the leather cutting operation, utilize this data to measure cutting performance and pinpoint areas for improvement, and detect anomalies early to make rapid real-time recovery decisions. Quality control serves as the guardian of material savings by ensuring that only the best cuts are used, maximizing both efficiency and product quality. 
 

Material variability 

Leather is a natural material, which means no two hides are the same. Adjusting the cutting process to accommodate these variations is crucial for maximizing material use. 

Changing designs 

Automotive designs are always evolving, and with them, the patterns for leather interiors. Keeping up with these changes while maintaining material efficiency requires flexibility and adaptability in the cutting room. 

Economic and environmental pressures 

The dual pressures of economics and environmental responsibility are constantly at play. Finding the balance between cost savings and sustainable practices is a challenge that manufacturers must navigate carefully. 

Embracing lean manufacturing principles 

Lean manufacturing is all about doing more with less. By adopting these principles in the cutting room, automotive manufacturers can streamline their processes and reduce waste. 
 
With Versalis, an automated process and integrated cutting solution can boost productivity by 35% and yield efficiency by 2.5%, all while enhancing durability. The all-in-one cutting line covers everything from hide digitization to cut-part offloading, incorporating automated scanning, nesting, and cutting operations to ensure maximum efficiency and minimal waste. 

Fostering a culture of continuous improvement 

A workplace culture that values continuous improvement will naturally seek ways to enhance leather-cutting processes. This mindset can lead to innovative solutions for material savings. 

Case studies: success stories in material savings 

1. Gruppo Mastrotto, a leader in the leather industry, faced challenges in meeting the ever-increasing demands for productivity, efficiency, and flexibility in their automotive division. To address these challenges, they implemented Lectra's Versalis digital leather cutting solution. According to Alberto Silvagni, Head of Gruppo Mastrotto's automotive business unit, the advantages of digital leather cutting include improved productivity, better efficiency in terms of raw material and leather usage, and greater flexibility to respond to constantly increasing customer requirements. This solution allowed Gruppo Mastrotto to optimize their cutting process, reduce waste, and adapt quickly to customer needs, ultimately enhancing their overall operational performance. 

Mario Levi, a prominent name in the leather industry, attributes much of their current strength and market penetration to the integration of Lectra's Versalis into their processes. Lele Ogliaro, the Director of Mario Levi, remarked, "If we hadn't integrated Versalis into our processes, we probably wouldn't be as strong as we are today or have the same market penetration." This integration has been crucial for enhancing their operational efficiency, allowing them to maintain a competitive edge in a demanding market. 

Conclusion: the road ahead for leather savings 

The automotive industry's journey toward maximizing leather material savings is ongoing. Manufacturers can make significant strides in reducing waste, saving costs, and promoting sustainability in their cutting rooms. 

Material savings in the automotive cutting room are not just about the bottom line; they're about meeting the demands of a world that expects both luxury and responsibility. With the right approach, technologies like Versalis, and mindset, the industry can continue to deliver the quality interiors customers love, in a way that's better for business and the planet.