Overview
Johnson Controls is one of the world`s leading suppliers of automotive interior systems, interior electronics and batteries.
Johnson Controls provides innovative, high-quality interior components and systems for cars, light trucks, sport utility vehicles, vans and mini-vans. the company design, engineer and manufacture seating components and systems, instrument panels and cockpit systems, door panels and systems, overhead components and systems, automotive electronics, electronic energy management systems, engine electronics and automotive batteries. JCI mission statement helps describe the passion and dedication that all 76,000 employees share and continually exceed customers` increasing expectations. This year alone, Johnson Controls will deliver components for more than 35 million vehicle units.
From concept through implementation, Johnson Controls delivers products that result in vehicle interiors where creating consumer preference and exceeding vehicle manufacturer requirements are the keys to added value. A single global process rapidly transfers best practices throughout the organization so the customers get best-in-class products no matter where in the world they operate.
At over 260 locations around the world, 76,000 employees, including over 6,000 engineers and designers, develop and produce seating systems, instrument panels and cockpits, door systems, overhead systems, automotive electronics and electronic energy management systems. From single components to complete interiors, Johnson Controls offers the broadest range of interior technologies and systems to vehicle manufacturers around the globe.
At the beginning of 1998, OptiTex™ launched the first OptiTex™ CAD installation in the Johnson Controls company. Today, OptiTex™ systems are installed in more the 20 different Johnson Controls plants world-wide with an estimated total of over 100 working stations.
Throughout the years, OptiTex™ CAD system repeatedly surpassed technological performance when compared to other well-known and well-established CAD systems such as Gerber, Lectra, Investronica and Assyst.
Stage one: Johnson Controls European cutting plants start working with OptiTex™ software
There were many key reasons why Johnson Controls choose to use OptiTex™ CAD software. The main requirements were flexibility, windows base, and user friendly, competitive price, independent software etc but, the first reason was OptiTex™’s capability to import all other CAD system’s AAMA/DXF files while other tested CAD systems couldn’t or had difficulties.
Since Johnson Controls works with many suppliers and subcontractors who were using various different CAD systems, there was a huge problem in being able to send, receive, and convert patterns between Johnson Controls different plants. The only system that succeeded in this unique importing process between the different CAD systems was OptiTex™.
The reason for this is because OptiTex™ is hardware independent software. OptiTex™ systems include more than 20 different types of drivers compatible for almost any existing software (Gerber, Lectra, Investronica etc) and hardware format (ie. Digitizers, cutters, plotters etc.). This flexibility of being able to read files enabled Johnson Controls to start using the OptiTex™ system throughout Johnson Controls European cutting plants.
During this process of replacing Johnson Controls European cutting plants software from, Gerber, Lectra and Investronica to OptiTex™ software, Johnson Controls tested and discovered OptiTex™’s Nest++™ actually had the best automatic nesting solution for the automotive care seat industry.
Nest++™ was found to have a perfect automatic nesting solution for their production and costing needs. For this significant reason, Johnson Controls European cutting plants again purchased, trained and implemented on Nest++™.
Stage two: Johnson Controls pattern designers start to work with OptiTex™ PDS
Johnson Controls European cutting plants began working with OptiTex™ Import and Nest ++™ modules. However their pattern designers were using an Assyst system.
Again, the design plants and the cutting plants were using different CAD software, causing tedious, time-consuming & unnecessary AAMA conversions between OptiTex™ and Assyst. Although AAMA conversions between OptiTex™ and Assyst worked, Johnson Controls sought for a better solution in order to avoid unnecessary data conversion which always leaves room for mistakes.
Johnson Controls decided to further evaluate OptiTex™’s PDS system for its pattern designs which so far were using only for AAMA data conversation and digitizing paper patterns. The testing of OptiTex™ PDS software showed that, not only was OptiTex™ software a much more user-friendly software, it’s also a powerful CAD software which offered unique seam utilities, specialized CAD tools like trim function, trace segment functions and remarkable cutting tools for improving the overall cutting process.
The decision to start using OptiTex™ in Johnson Controls plants was done by Mr. Willy Van-Looy, who is the Group Engineering/Manufacturing Manager Europe & Trim Plant Launch.
A Short Interview with Mr. Van Looy:
Question: Why did you choose to use OptiTex™ software?
Answer: Due to the fact that OptiTex™ was an independent software supplier (no CAM systems, no restrictions), we saw more flexibility in relation to improvements and changes. Furthermore, the service of a company and the fast reaction on change requests are one of the most important drivers in choosing a supplier for Johnson Controls. OptiTex™ during this phase was very cooperative and flexible with our needs.
Another very important matter is the simple, user friendliness of the package. The less training a starting CAD-Operator needs to understand the system the better. The more difficult, or complicated the software is, the less people will be able to use the benefits, and the less money we can gain in our process.
Question: In your point of view, what are OptiTex™’s advantages when compared to the other CAD systems in the market today? And what are to your opinion the most powerful OptiTex™ advantages.
Answer: The compatibility with other software packages available on the market. Also, OptiTex™ was one of the first companies which made the step to a Windows environment. But the most powerful advantage is the flexibility and support of the company.
Question: What do you think is the key for OptiTex™ future success?
Answer: OptiTex™ will continue having a bright future if they “keep on meeting the increasing customer expectations”. To keep up the flexibility, to continue the research & development of new products and to have an open communication with vendors will ensure success for OptiTex™.
Question: What made you decide to replace the well established companies such as: Gerber, Lectra, Investronica and Assyst, with OptiTex™ software?
Answer: Prices, willingness and reaction speed to make changes, user-friendly product openness to integrate our needs.
Question: Can you describe the replacement process? And how did you convince your staff that this change is necessary to Johnson Controls organization? And did it goes smoothly?
Answer: Replacement process was step by step. First we changed plant by plant the software in combination to use a converting software. Later we changed as well the systems in our releasing department, to have a fail save data streamline between our Headquarters and the Plants. You will have always pro`s and con`s in every organization to implement new tools. The question is to find the best tool for the job, and then it is always easier to get "the buy in" of the colleagues.
Question: How do you find OptiTex™ product support?
Answer: Positive, and with the Belgium satellite this can only improve.
