Muebles Liz quadruples production capacity with Lectra

• Functional Applications - Manufacturing Execution Systems (MES)
• Functional Applications - Product Lifecycle Management Systems (PLM)
• Functional Applications - Remote Monitoring & Control Systems

• Process Manufacturing
• Quality Assurance

• Manufacturing System Automation
• Predictive Maintenance
• Process Control & Optimization

• System Integration
• Training

With an automated cutting solution in place, which was already more than 10 years old, Muebles Liz’s ‘just-in-time’ production was struggling to satisfy customer orders. In addition, their existing cutter was being used for fabric only, leaving nonwoven and other materials to be cut by hand. The main growth objectives were to improve product specifications both in terms of quality and price, and to be more competitive in the market. The main challenge was to meet demand, for which they were logging a lot of overtime hours from manual cutting labor. To overcome this challenge, the Muebles Liz team was looking to acquire a new automated cutting system. Working with Lectra experts it became clear that a new system was only one part of an overall solution and that Lectra’s expertise and know-how could bring even greater benefits. An in-depth analysis of the company’s current production processes formed the basis for a tailored action plan which enabled Muebles Liz to reduce operational costs by improving productivity through more efficient production processes.

Muebles Liz is a leading Mexican upholstered furniture manufacturer known for its high-quality products and competitive pricing. The company has been in the industry for several years and has built a reputation for delivering top-notch furniture to its customers. Muebles Liz operates on a 'just-in-time' production model, which requires precise and efficient manufacturing processes to meet customer demands promptly. The company employs a significant workforce and has been striving to improve its production capabilities to stay competitive in the market. With a focus on quality and customer satisfaction, Muebles Liz has been continuously looking for ways to optimize its manufacturing processes and reduce operational costs.

Lectra’s consultant analyzed all Muebles Liz's processes, including interviewing production staff to identify activities that added value and those which did not. Lectra suggested areas for improvement not only for the cutting department but for the entire manufacturing process. By following Lectra’s recommendations for optimizing their processes, Muebles Liz was able to eliminate non-value-added activities, increase production capacity, and achieve better product quality. These improvements were made possible by applying lean manufacturing principles and using assessment methods such as DILO (Day In the Life Of) studies, Value Stream Mapping, and analysis of overall equipment efficiency. Key Performance Indicators such as process time and cutting capacity were agreed to with Muebles Liz at the outset and monitored continuously throughout the project. The combination of hardware, software, and Lectra’s specialists helped Muebles Liz greatly in streamlining their processes.

• Muebles Liz tripled the number of plies they cut, from 18 to 60.
• With VectorFurniture, cutting time per set is six times faster than manual cutting.
• Muebles Liz now produces 400 sofas and 1200 cushions per day with VectorFurniture, whereas previously they were only producing 300 sofas and cutting all cushions by hand.

• 300% increase in cutting capacity.
• 16% reduction in cutting cycle time.
• Elimination of manual cutting and consequent staff overtime hours.