Kübler relies on digitalization with Assyst

Workwear with an innovation factor

The Paul H. Kübler Bekleidungswerk GmbH & Co. KG develops high-quality occupational and protective clothing for all groups of people whose professional environment is characterized by extreme physical stress or strong external influences. The German-based workwear specialist focuses on safety, functionality, innovation, and working comfort for the individual. Protective functions and standards are combined precisely according to regulations and requirements for every product development. Special designs are also developed for tool bags, individual motion sequences, and on high-wear areas of the garments. The working environment and temperature are also taken into account in the selection of materials and the design concept.

For individual customer requirements, the specifications of existing articles are adapted or new products are developed. The existing range of variants and sizes is correspondingly extensive. A selection of the Kübler range is also available to private individuals in specialist shops, the company’s own e-store, and in DIY stores.

A modern CAD system can be the key to more efficient pattern making department operations. The goal is to provide digital support throughout the processes to create the conditions for future-oriented working, such as automation, data flows in the supply chain, and full integration with ERP and EDI. This is why Kübler is switching from investronica and Optiplan to Assyst technology. The company is planning one end-to-end process from pattern development to production with Assyst.CAD, Autocost, and Automarker.

Pattern system change, from Investronica to Assyst.CAD

Changing the CAD system affects all the product lines, meaning it has a considerable impact on the core process of Kübler’s product development. Together with the experts, the project managers Manuela Banzhaf and Julia Stuckenberger prepare the project in great detail to try and address all possible scenarios as early as the planning stage. The challenge here is that the “old” and “new” CAD worlds must operate in parallel for some time to avoid disruptions to day-to-day business.

This was the first CAD change for us. The Assyst team has a lot of experience with this changeover and that helped us a lot, ensuring that we got the results we had visualized.
Manuela Banzhaf, Team Lead Business Project Management, Kübler Workwear

For Kübler, modernizing the CAD system means more than just replacing the software. For a seamless, end-to-end process, the company also needs clear data structures, so the project will streamline and reorganize the cutting landscape that has evolved over decades. The pattern maker team receives intensive Assyst.CAD training from the outset, enabling them to actively shape the change.

CAD: Modernizing pattern management

Together with the Assyst experts, the Kübler team first consolidates the basic patterns, reduces the number of grade rule tables, and creates a new naming logic with a database and attributes. In the past, the patterns were stored in automatically generated number formats and could only be found using an additional program – but the pattern maker team uses Assyst.CAD to define grade rule and measurement tables as uniform standards, to name all pattern pieces, styles, and models according to a uniform ‘speaking’ system and manage them in the Assyst.CAD database.

In the second step, the pattern pieces are converted, starting with basic pattern and models to facilitate the learning process. The pieces are exported to AAMA and stored in the design file there. Each individual pattern is manually reworked during the conversion process. Line guides, markings, grading values, etc., are adjusted, the naming logic is assigned, and the BOM is updated. All the transferred data is thoroughly checked, so that a production-ready pattern can finally be stored in the database.

Once the conversion has been approved by the pattern maker team, the planning and work preparation departments can start production using the new Assyst way.

Automarker: Automatic marker placement and end-to-end order optimization

The introduction of Assyst.Autocost (order optimization) and Assyst.Automarker (marker placement) is also accompanied by intensive training. Together with Assyst, the marker making team stores the necessary parameters for the Kübler markers in Automarker. Autocost is integrated into the existing ERP system. At the same time, Kübler carries out internal and external periphery tests for linking plotters and cutters. To achieve this, markers from both systems are sent to production facilities which plot and compare them. Approval takes place after the dimensions of the plots have been tested, the pattern has been cut successfully and the production of this small test order has been completed.

By switching to Assyst.CAD, we’ve reorganized our development and also set new priorities. Assyst has been with us every step of the way and has responded exactly to our needs. The cooperation, consultation, and familiarization with the new systems were perfect.
Julia Stuckenberger, Team Lead Pattern, Kübler Workwear

The result? Improved workflows, modern processes and a readiness to embrace digital innovation

The joint project is a great success. All departments pull together and also abide by the company motto: Make work better. Questions of all kinds are answered by the Assyst team in workshops and training courses on an individual basis.

The new way at Kübler

Today, Kübler uses Assyst end-to-end technology. When styles or models are approved in CAD, the production order from INTEX (ERP) flows into Autocost along with the pattern data for order optimization and consumption calculation. The markers are taken directly from Assyst.CAD, laid in Automarker and then transferred to the partner’s facilities.

In Assyst.CAD, all the Kübler pattern pieces are now clearly laid with consistent names. In this way, variant pieces can be managed more easily, improving future product development: Customer-specific adaptations, e.g. pocket shapes, carrying straps, etc., can be easily added and assigned. For custom-made products in special sizes, the coming year will see Kübler introduce Assyst.MtM, Assyst’s made-to-measure program. This will enable the company to also work with a higher level of efficiency here as well.

Thanks to Assyst.CAD and our project, we now have a very good understanding of our basic pattern again. We are well-known in the market for variants and individual modifications – and we can now implement these more easily, with no need for complex controls. The best thing about it? We’re now enjoying our work even more!
Julia Stuckenberger, Team Lead Pattern, Kübler Workwear

With Assyst technology, we’re well-positioned to grow as we move into the future. The end-to-end process from pattern to marker placement and order planning is very important for us. Errors can no longer occur and we have full cost transparency for customer quotes.
Manuela Banzhaf, Team Lead Business Project Management, Kübler Workwear

Instead of the usual 45 grading tables, a well-structured and considerably reduced number of grading tables now cover the ten relevant size ranges uniformly and clearly. The catalog and marginal sizes have also been redefined, so that production orders can now be better documented and the requirements for a full EDI integration fully met.

The next step – process expansion

In the next step, the end-to-end process at Kübler will be expanded in the direction of supply partners, and the connection of third-party systems will be extended. The new digital competence of the employees and the integrated technology landscape create the optimal conditions for exploiting the opportunities of digitalization, thereby realizing new competitive advantages.