To maintain its position as one of the most well-known and versatile childrenswear brands in the growing Chinese market, Tongtai implemented 14 Lectra cutting machines over the last decade and recently engaged in a Lectra Power Advanced service subscription. The double focus on technology and maintenance has helped them increase production flexibility, volume and speed without sacrificing profitability and quality.

Customer Story

TongtaiMastering the Art of Childrenswear with Smart Manufacturing

The challenge

Results

Lectra’s response

The Chinese childrenswear market has grown exponentially because of the country’s emerging middle class and adoption of its two-child policy. Facing harsh competition from an onslaught of new brands entering the market, Tongtai Infant Finery Co., Ltd had to strengthen its position as a key industry player by meeting increasing consumer demand within shorter time frames. The company decided to invest in machine maintenance for its automated cutting room in order to reduce machine downtime while handling larger-volume orders and increasing its production speed.

Tongtai has transitioned successfully to a fully automated cutting room, thanks to the 14 Vectors they have implemented. The company engaged in a Lectra’s Power Advanced service subscription, which offers real-time support and maintenance for these machines, improving machine availability and providing best-in-class machine uptime while reducing manufacturing disruption. This two-pronged investment approach in both technology and maintenance has helped the company keep up with the growing market demand by dramatically reducing time to market and enabling them to produce more.

The Lectra Power Advanced service subscription guaranteed preventive maintenance by installing and replacing parts, and providing audits and reports for every 500 hours of cutting time. In terms of predictive maintenance, Lectra offered real-time monitoring and alerts. Users received monthly calls, activity reports, on-site visits and annual maintenance reviews.

About LectraFor forward-looking companies that breathe life into our wardrobes, car interiors, furniture and more, Lectra is committed to crafting the premium technologies that facilitate the digital transformation of their industry. Lectra’s offer empowers brands and manufacturers from design to production, providing them with the market respect and peace of mind they deserve. Supporting the fashion and apparel industry, Lectra offers PLM and CAD software, cutting room solutions and expert services to create, develop and produce garments, accessories and footwear. Founded in 1973, today Lectra has 32 subsidiaries across the globe, serving customers in over 100 countries. With nearly 1,700 employees, Lectra reported revenues of $313 million in 2017. Lectra is listed on Euronext (LSS).

® Vector is a registered trademark of Lectra.

A Pioneer in Smart Manufacturing for ChildrenswearHebei-based Tongtai Infant Finery Co., Ltd has been a major player in the Chinese childrenswear sector since its early beginnings in 1986. With an annual production capacity of over 30 million garments and an impressive product range of almost a thousand items including infant clothing, accessories, and baby care products, the company boasts an annual revenue of 600 million yuan (US$ 87.3 million).

They were the first company to venture into automatic cutting in Hebei when they bought their first Lectra cutting machine in 2006 and has never looked back since. “There are three reasons why we like our Vectors so much. Firstly, their high quality and durability mean less fabric waste and machine downtime. Secondly, their fast cutting speed. Thirdly, they’re simple and foolproof to use, so this increases overall efficiency,” attests Li Shuangrui, the vice president of Tongtai.

Using Machine Maintenance as a Competitive AdvantageThe company decided to uphold their machines’ optimum cutting quality and speed by seeking Lectra’s Power Advanced services. By being able to detect and avoid technical hiccups ahead of time with Lectra’s constant technical support and maintenance, Tongtai was able to ensure that there was maximum uptime and minimum disruption. “We believe that machine maintenance should be put in the hands of professionals, so we can focus entirely on the production process,” notes Li.

Partnership for a Leaner FutureThe Power Advanced service subscription has marked the beginning of a strategic partnership between Lectra and Tongtai. Lectra is now playing a bigger role in the company’s production strategy by also providing insight into Tongtai’s cutting activity via real-time monitoring. Together with Lectra’s technology, lean management expertise and technical support, the company is confident about their future.

“Ever since we bought our first Vector, the idea of turning to other vendors has never crossed our minds. The quality of their technology and customer care services has always been premium and thanks to them, we’ve managed to take our first steps towards Industry 4.0,” says Li. “Now that we have the best-in-class machinery, it’s time for us to focus on our software, which we would like to explore now with Lectra, given our experience with them.”

“Ever since we bought our first Vector, the idea of turning to other vendors has never crossed our minds. The quality of their technology and customer care services has always been premium and thanks to them, we’ve managed to take our first steps towards Industry 4.0.”

Li Shuangrui, Tongtai Infant Finery Co., Ltd

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