By Industrial Print Magazine Staff
Part 2 of 3
Manufacturers overhaul production lines for many reasons. Perhaps the most obvious is to streamline operations while remaining profitable and maintaining a loyal customer base. Eliminating/minimizing manual processes is one way to do so. Automation through digitization is popular.
Digitizing a manufacturing facility can be advantageous when executed properly and for the right reasons. For example, any company looking to cater to the recent boom in made-to-order, customization, or personalization should consider implementing digital, automated software and/or hardware.
The Sofa Solution
Established in 2004, Stoffus celebrates over 20 years of experience in the design and manufacturing of leather and fabric sofas in the Portuguese market. It relies on a combination of quality, design, comfort, and durability in order to provide customers with the best final solution.
In February 2020, the company opened a new facility and digitally transformed their processes with the objective of improving working conditions and growing their business. Stoffus implemented Gerber Technology, a Lectra Company’s end-to-end digitized hardware and software solutions to enable made-to-order production, improve quality, and realize material savings—AccuMark and AccuNest software as well as a GERBERcutter Z1.
Gerber AccuMark is a two-dimensional (2D)/three-dimensional (3D) CAD solution. It offers pattern design, grading, marker making, and production planning software. The AccuMark 3D version elevates design, offering realistic virtual renderings directly from 2D pattern data.
Gerber AccuNest is an automated, high-speed nesting system that uses algorithms to analyze multiple nesting solutions and yield one with the highest material utilization. The solution is designed to respect all material constraints applied to pieces such as directional rotation, tilt allowances, and spread.
The GERBERcutter Z1 is a single-ply cutting system for apparel production. The automated solution is equipped with GERBERconnect remote diagnostics to ensure the device is in top working order. Increasing efficiency and optimizing cutting processes, comprehensive reports analyze system throughput, material yield, processing times, and individual job statistics.
With the Gerber solutions in place, Stoffus has seen a 50 percent reduction in manpower, an improved material savings between one to 1.5 meters per sofa, and a 100 percent increase in productivity. 25 to 30 sofas are produced daily instead of previously manufacturing 15.
Timing is Everything
Around the same time that Stoffus opened its new facility, COVID-19 was gaining traction. Despite a global pandemic, the furniture manufacturer was able to leverage its new automation technology to keep its normal business operations on pace as well as keep up with a growing demand for made-to-order furniture.
With more consumers requesting modular and customizable products, Stoffus offers a customization service as well as a collection where it is possible to customize colors, fabrics, ergonomics, functions, decorative details, and desired measurements.
Prior to working with Gerber automation solutions, the manufacturer was manually processing these custom orders, which was time consuming and difficult to keep delivery times in check as demand grew.
Instead of standing still or worse going backwards, Stoffus doubled its production capacity when it digitized its supply chain. Placing its trust in Gerber was a win for the company. ‘‘Speed, quality, optimized and integrated processes, combined with excellent service were the decisive reasons for choosing Gerber as a partner over the competition,’’ says Luis Salgado, CEO/founder, Stoffus.
Record Time
With the help of Gerber automation solutions, Stoffus delivers sofas to its customer base in a timely fashion. Better yet, the furniture caters to the made-to-order trend and still arrives in record time.
We continue our series on manufacturers benefiting from automation solutions with a third and final profile on an outdoor goods manufacturer.
Read part one of this series, Weathering the Digital Era.
Sep2021, Industrial Print Magazine