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Nestled in the picturesque landscape of Bordeaux, Lectra’s production site in Cestas is the beating heart of the Vector solutions designed for the textile and apparel industry. Much like the master winemakers who blend tradition and innovation to craft prestigious wines, Lectra combines cutting-edge technology and automation to create bespoke cutting systems that are transforming production processes. We stepped onto the factory floor in Cestas, where technological excellence is crafted with precision, reaffirming the company’s commitment to Industry 4.0.
Cestas is home not only to one of Lectra’s three production sites—the other two being in Tolland, USA, and Suzhou, China – but also its only Innovation Lab, where all software is developed. It also houses one of its five international experience centres – the others are in Milan, Italy; Tolland and Atlanta, USA; and Shanghai, China – as well as one of its 12 expertise centres.
The Cestas production site is a hub of innovation, serving primarily as the assembly line for Vector and Versalis cutting systems. The entire production process is managed by the Manufacturing Execution System (MES), which optimises operations by monitoring real-time data such as operational status, equipment efficiency, and product quality. This system follows Lean Manufacturing principles, aimed at eliminating non-value-added activities, and adopts an On-Demand approach to provide tailored solutions to meet each client’s needs. “For example, our 9-metre machine is designed in modules, making it easier to transport and assemble. This flexibility is key, as we cater to a wide range of clients, from mass producers like denim manufacturers to brands that require more diversity in their cutting solutions,” explained Cathie Calas, Experience Centre Project Manager. “Operators digitalise production orders and have access to all the necessary information for assembly, such as the instructions for mounting Vector heads, including visual guides and estimated task times. Efficiency is further enhanced by the use of barcodes for all operations, ensuring rigorous control,” she added during a tour for media, invited to see the unveiling of Valia Fashion.
On the production line, two robots feed different assembly stations, ensuring that the necessary components are delivered quickly and precisely. “These robots play a crucial role in internal logistics,” stated Cathie Calas. “They pick up and deliver boxes of components, allowing operators to focus on assembly rather than worrying about transporting parts,” she explained.
The automation at Lectra’s Cestas production site extends beyond machine assembly, covering the efficient provision of small tools and protective materials. This integrated system allows operators to access required equipment swiftly through a connected network that monitors stock levels in real time, ensuring everything is available to maximise productivity and safety. “Connectivity is key to our operational performance, as it not only optimises material supply but also boosts overall production efficiency, enabling operators to focus on what truly matters: quality and precision in assembly,” emphasised Calas as she guided the tour through the factory floor.
Lectra’s Cestas facility operates with a network of more than 270 suppliers, most of whom are in France and Europe, in a strategy that prioritises nearshoring.