Case Study: Tachi-S Mexico achieves 1,000 car seat sets/day and higher efficiency with Lectra

Tachi-S Mexico Fulfills Growth Potential With Lectra

Tachi‑S Mexico, a leading automotive seat supplier, faced capacity constraints as demand in Mexico surged: an unoptimized cutting room produced low equipment efficiency, high fabric consumption and quality defects that threatened planned growth. With baseline equipment efficiency around 56% and daily output near 550 seat sets, the company sought ways to boost production without excessive capital expenditure.

Lectra consultants conducted in‑depth process analyses using lean tools (DILO, Value Stream Mapping, OEE) and delivered a tailored action plan plus two new Vector cutting systems. After two consulting phases, equipment efficiency climbed to 72% and production rose to about 1,000 seat sets per day (phase 1 alone added 275 sets/day and cut cost per set by $0.38). Additional gains included material improvements of 50%, 120% and 137% on three fabrics, 70% equipment availability, an average 109% increase in plies, and identified opportunities to reduce fabric use >3% (1% saving ≈ $100,000/yr).

Tachi-S

Luis Soria

Senior Corporate Purchasing Manager