Textile cutting ecosystem

Context

The SPLICE system was implemented in textile manufacturing plants where spreading and cutting processes were managed manually. Material loss was significant due to incorrect overlaps, lack of clear defect tracking, and unoptimized machine settings.

Main challenge

• High setup and reconfiguration times for marking
• No real-time visibility of material consumption
• Significant material loss caused by untracked defects and incorrect splicing
• Difficult sensor recalibration and lack of synchronization between machines

Solution

• Role-based authentication (Operator, Maintenance, Administrator)
• Automatic loading of CUT / MRK files from CAD systems such as Accumark or Optitex
• Step-by-step guidance for defect, splice, and splice reversal operations
• Progressive sensor calibration with dynamic correction points
• Manual consumption mode for exceptional scenarios
• Full roll traceability + ZPL label generation
• Automatic synchronization between local and global databases
• Real-time reports on efficiency, consumption, and material savings

Lean applicability

• Waste elimination (Muda): automated and precise overlap calculation, digital defect management → direct material loss reduction
• Kaizen: progressive sensor calibration + periodic reports → continuous optimization
• Standardization: unified procedures for splice, defect handling, and roll changeovers
• Continuous flow: real-time synchronization between databases and machines
• Visual management: intuitive interface with color codes and step-by-step instructions

Also applicable in

• Textile industry (fashion, automotive seat covers, airbags, etc.)
• Composite materials manufacturing (aerospace, technical furniture)
• Premium upholstery / furniture production
• Technical and insulating material production (filters, neoprene, kevlar, etc.)
• Industrial plants with high traceability and standardization requirements (OEM & Tier 1)

Results

• Financial impact: €15,000–50,000 per company / year / machine
• Material waste reduction: 3–8%
• Setup time reduction: 20–30%
• Productivity increase: 15–25%

Context

Before implementation, companies were facing:

• Manual cutting — slow and imprecise
• High material waste (15–20%)
• Critical dependency on highly skilled operators
• Inconsistent quality and long processing times
• Lack of process standardization across operators and shifts

These challenges led to high production costs and limited competitiveness in the market.

Main challenge

• Lack of an automated and scalable cutting system
• High dependency on manual labor, preventing digital integration and scalability
• Significant material losses affecting profitability
• Inability to ensure consistent quality at higher production volumes

Solution

A fully automated cutting system — Automatic Bumper — was implemented, integrated with the internal Splice System software, enabling:

• Maximum digital cutting precision
• Elimination of unnecessary material losses
• 100% standardized and repeatable process, independent of operator
• High scalability across multiple flexible material types

Lean applicability

• Waste elimination (material + time)
• Full process standardization, independent of operator skill

Also applicable in

• Textile industry
• Composite materials manufacturing
• Upholstered furniture production

Results

• Material waste reduced to below 5% (from 15–20%)
• Productivity increased through significantly faster cutting times
• Consistent cut quality — eliminating human variation
• Average saving: ~€15,000 per year per installed system

Context

• Picking relied on operator memory and complex paper instructions.
• This led to incomplete or mixed boxes, extra material usage, and delays in the production flow.

Main challenge

• Eliminate dependency on operator experience and manual identification.
• Manage a dynamic workflow with frequent design changes.
• Develop a user-friendly system, accessible even to new operators.

Solution

A digital system with three interconnected modules that integrate post-cutting operations with internal logistics through color-coded visual guidance and real-time data synchronization.

Administration

• Configuration of IP settings, database connections, and user access.
• Centralized management of part numbers (PNs), colors, and location mapping.

Production operators

• Automated marker projection on the collecting table.
• Each piece is color-coded (up to 8 colors) according to its PN.
• Visual guidance enables fast and error-free identification and picking.

Logistics

• Desktop application and mobile scanner for digital location mapping.
• Automatic linking of part numbers (PNs) to their rack / box locations.
• Full traceability, color-matched sorting, and validation at process end (via digital or stamped picking sheet).

Lean applicability

• Visual management: color-based projection enables fast and accurate recognition.
• Standardization: unified process, independent of the operator’s experience level.
• Waste elimination: reduction of scrap, elimination of rework and unnecessary handling time.
• Flow: continuous process without interruptions caused by picking errors.
• Error proofing (poka-yoke): visual guidance prevents incorrect selections.
• Lead time: shorter handling and sorting times after cutting.

Also applicable in

• Textile manufacturing — CNC-cut fabric pieces requiring quick visual identification
• Automotive — small components with multiple part numbers and high-mix production
• Furniture & packaging — similar-shaped pieces with high mix, risk of confusion
• Sheet metal processing — aluminum, steel, or composite panels
• Plastics & plexiglass — color-coded separation of transparent or similar-looking pieces
• Foam & insulation — multi-layer cutting where visual guidance simplifies sorting
• Leather & synthetic materials — visual identification for sets, variants, or batch grouping
• Signage / graphic — precise sorting of cut vinyl or printed sheet materials
• Electronics / cable assembly — visual coding for small cut parts, panels, or labeling boards
• Wood & MDF — sorting similar furniture parts, panels, or decorative elements

Results

• Picking errors eliminated → 0 mixed or incomplete boxes
• Direct material savings → ~5% waste reduction
• Training time reduced → from several weeks to a few days
• Improved reliability and traceability throughout the entire logistics flow
• Overall: improved process reliability, reduced waste, and enhanced production efficiency