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Ethan Allen deploys Plataine TPO for fabric nesting optimization
27
Jul '09
Ethan Allen completes the deployment of Plataine's TPO solution for automatic nesting and roll-pick optimization in its two upholstery manufacturing plants - in Maiden, NC and Silao, Mexico.

Plataine's Total Production Optimization (TPO) Solution offers Upholstery manufacturers an integrated solution for optimal nesting and roll-selection of the fabric needed to meet the ever-changing stream of incoming customer orders.

“TPO allows us to meet the market demands for customizable orders, without compromising productivity or resource utilization.” says Cliff Thorn, VP of Upholstery Manufacturing at Ethan Allen. “Since going-live with TPO, we have consistently increased our material utilization by over 6% through optimized nesting, and achieved additional savings through methodic reduction of short-end rolls in our warehouse. With TPO, 15% of today's work-orders are nested over more than one roll, utilizing fabric that would have otherwise been written off.”

Seamlessly integrated to the manufacturer's ERP/MRP systems, TPO matches the daily order demand with current fabric roll inventory and generates an optimal selection of inventory-rolls to use and for each roll - an optimal nest that matches the orders' size, style, dye, match codes and other parameters. In doing so, TPO drives significant cost savings and increased productivity by offering higher material utilization, better inventory management, and faster - more flexible - time to market by automating routine manual tasks and eliminating any errors associated with it.

Randy Rose, Plant Manager at Ethan Allen's Maiden facility adds that “in addition to driving material savings, TPO helps us automate a set of manual-intensive processes inherent to customized furniture manufacturing. TPO automatically picks up on custom requests for different designs, fabrics and options, and then selects and nests the necessary pieces – all at one go and without costly mistakes. This, of course, also improves our level of customer service.”

"TPO's robust combination of process automation and resource optimization helps Ethan Allen control costs in these volatile times, while also setting the stage for a future economic recovery and increased production." says Avner Ben-Bassat, Plataine's President. “We are excited with Ethan Allen's success in using our software and will continue to work with the Ethan Allen team to fulfill their corporate vision for excellence and innovation.”

Ethan Allen Interiors Inc is a trendsetting interior design authority. A strong American brand for more than seventy-five years, Ethan Allen is a global company that manufactures approximately sixty-five percent of its products in its United States plants.

Plataine is a leading provider of production optimization solutions for manufacturers of metal, wood, textile and composite-material products. Plataine's production optimization solutions enable manufacturers to be more competitive by increasing material utilization, improving productivity, and shortening manufacturing cycles to ensure on-time delivery of products to customers.

Plataine Software


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