The production line of the Automotiveindustry determines the cycle in the warehouse. The quality of the replenishment processes, order picking and punctual delivery to the line are the primary goals of intra-logistics. The smooth material supply of the standard parts to the line must also be guaranteed. With a high variety of variants, sequencing in the warehouse must be guaranteed with 100% certainty. Sequence wagons and shopping carts are created and placed on the line with a route train to match the cycle. Frequently, external service providers take over these tasks.

Poka Yoke in Automotive

In order to ensure the quality of various work processes, many methods have been developed worldwide. One of the leading philosophies in the problem was developed in Japan by Shigeo Shingo from 1961 to 1964. Today, many work processes are planned and implemented according to the Poka Yoke principle. LUCA supports with many picking systems and their combinations (Pick-by-Light, Pick-by-Frame®, Pick-by-Point®, Pick-by-Voice, etc.) the suitable processes with error avoidance according to the Poka Yoke principle (further on Wikipedia).

Shopping Cart (KIT)

Depending on the model variant, a shopping basket (KLT Automotiveor special box) is usually created in a "supermarket" (SuMa). All parts of the different variants are stored in the storage area. The task is to pick the matching parts into the shopping cart (KIT) and then place the finished shopping cart in the correct position for the line sequence. Picking with small quantities is not allowed. Here, people still often work with a piece of paper in single order picking. Various systems are available to increase the quality of picking and to support the employees: Pick-by-Scan, Pick-by-Light (multi-user), Pick-by-Voice, Pick-by-Watch, Pick-by-Tablet. The selection of the appropriate technology is worked out in workshops and possibly tested in pilot plants.

Multi-Sequence-Picking (RACK)

The individual parts and large parts are picked directly into the compartments of a sequencing trolley (RACK). In a RACK, parts for N vehicles are collected in N compartments. With route-optimized sequencing, several parts are often removed simultaneously from one storage compartment and placed in different target compartments in the RACK. Paper lists are not well suited for the process in the Automotivepaper lists. To ensure quality when using paper lists, a SuMa often switches to a single-seqeunce method (tray by tray). However, this results in very high losses of time due to the repeated walking paths in order to remove the same parts. Sequencing errors cannot be avoided with personnel who often rotate.

The picking of the RACK's with an optimal multi-sequence picking method should be supported technically. Various solutions are available for this, above all: Pick-by-Frame®. The very efficient and high-quality method is very well suited for use.


In some cases, employees in the warehouse carry out various small pre-assemblies of the components, which then have to be delivered to the lines pre-assembled in a suitable sequence. Various solutions Automotiveare available to support the organization and processes of assembly activities (Pick-by-Light, Pick-by-Voice, Pick-by-Frame®, etc.). Just talk to us about it.

Shoring documentation

When pre-assembling the components, Automotivethe shoring documentation must often be used as proof (e.g. pre-assembly of the side mirrors with electronic assistants). In the case of pre-assembly, workplaces are set up with measuring equipment. The results are saved according to the regulations with long-term backups. LUCA offers many possibilities to design these workplaces.