Case study : K-LINE

K-LINE: Every reduction in waste translates into sustainable performance

K-LINE, a subsidiary of the Liebot Group and the French leader in industrial joinery, manufactures entry doors, sliding doors, and windows for new construction and renovation projects at seven production sites in France: Lima, City, Ouest Alu, and the four Prima plants. Aluminum, a key component of its products, is becoming increasingly scarce, and its price fluctuates significantly. Reducing scrap rates has therefore become a strategic priority.

Products and Materials

Front doors, sliding doors, and windows made of aluminum and PVC.

Machines

Dubus, FOM, Emmegi, Schirmer

Computer Tools

Microsoft Dynamics AX2009 and AX2012 (ERP), MX, and Matrix (MES).

Main objectives

Reduce the drop rate by at least 2 points in total
Reconcile theoretical and actual material consumption in real time, with a centralized view across all 7 sites
Reduce the volume of new bar stock returned to inventory (RAB) and associated unnecessary handling
Digitize real-time tracking and characterization of scrap
Adjust production runs for lacquered profiles to align as closely as possible with actual demand
Simulate planning and batching scenarios to optimize material yield.

K-LINE's industrial challenges

K-LINE needs to move away from a static materials management system that relies on segmented data across various information systems (ERP, MES, WMS) and is reported retrospectively via a BI system.

K-LINE needs a Material Management System (MMS) that can reconcile planned and actual figures across all its sites, in order to respond quickly to discrepancies between planned and actual output.

Failure to include scrap in net requirements calculations results in excess inventory and unnecessary handling. With a target of reducing scrap by 2 points and the introduction of Coralium recycled aluminum starting in May 2026, the challenge is to establish a unified materials management framework across the group’s 7 sites.

Results - Material savings

175 metric tons of aluminum saved in 12 months

A 2-point reduction in the fall rate

735 metric tons of CO2 equivalents avoided

€700,000 per year saved on material procurement costs*

*At a market price of €4,000 per metric ton, excluding tax

Results - Operating income

One year after the solution was rolled out, K-LINE is already seeing tangible operational results.

Reduction in material purchases

Every disposal site saved directly reduces the purchase of new materials.

Optimizing batch composition

Planning simulations optimize material yield before each production run

Forecast vs. actual comparison

The projected material consumption matches the actual figures.

+ 10 productivity points

The elimination of the RAB has reduced the number of new profiles returned and unnecessary handling.

Centralized multi-site management

A single dashboard to optimize material usage across the 7 sites.

Real-time fall rate monitoring

Tracking Fall Rates Using Reeverse's BI Analyses and Dashboards

The Material Management System provides a clear overview of material consumption (inputs to the cutting centers) and outputs (produced parts, technical offcuts, scrap, and reclaimed materials). It enables the calculation of material yield and scrap rate, which are essential for analyzing material performance.

The result is positive, with a 6.91% reduction in scrap rate between the current solution and the Reeverse Systems solution.

Additional gains are noted in productivity in the pre-processing area and during machining, with fewer batches to prepare and less weight to handle in terms of profiles and scrap.

The automatic integration of Reeverse Systems' batching calculations into our ERP system has saved us two hours with each run.

Case study: K-LINE