The production lines of the Automotive industry determine the pace in the warehouse. The quality of replenishment processes, order picking and timely delivery to the line are the primary goals of intra-logistics. Likewise, the system must also guarantee the smooth material supply of standard parts to the line. With a high number of variants, sequencing in the warehouse must be guaranteed with 100% reliability. Sequence trolleys and baskets of goods are formed and positioned at the line in line with the cycle using tugger trains. External service providers often take over these tasks.

Poka Yoke in Automotive

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

Shopping cart (KIT)

The formation of a shopping cart in the Automotive (KLT or special box) is usually done in a "Supermarket" (SuMa), depending on the model variant. In the storage area, the parts are stored in different variants. The task is to pick the appropriate parts into the shopping cart (KIT) and then to place the finished shopping cart matching the position in the line sequence. Picking with shortages must not occur. In this case, single-order picking is still often used today. In order to increase the quality of picking and to support the employees, different LUCA systems are available: Pick-by-Scan, Pick-to-Light System (Multi-User), Voice Picking, Pick-by-Watch, Pick-by-Tablet. The selection of the appropriate technology will be worked out in workshops and eventually tested in pilot plants.

Multi-sequence picking (RACK)

Small and large parts are picked directly into the compartments of a sequencing cart (RACK). In a RACK, parts for N vehicles are sorted into N compartments. In route-optimized sequencing, several parts are often picked from a storage compartment at the same time and placed in different target compartments in the RACK. Paper lists are not well suited for this process in the Automotive area. To ensure quality when using paper lists, a switch is often made in SuMa to a single-seqeunce method (tray by tray). However, this LUCA system results in very high time losses due to repetitive walk-throughs. With frequently changing personnel, additional sequencing errors cannot be avoided.

The picking of RACK's with optimal multi-sequence picking should be supported by technical means without fail. Various solutions are available for this, above all: Pick-by-Frame®. The very efficient and high-quality method is very well suited for the application.


In some cases, after picking, warehouse employees perform various assembly operations on the components. These are then delivered to the lines in the appropriate sequence. For the Automotive area, various solutions are available for the support, organization and system processes for the assembly activities (Pick-to-Light, Voice Picking, Pick-by-Frame®, etc). Just talk to us about it.

Shoring documentation

When pre-assembling technically sensitive components, the automotive industry often requires installation documentation (e.g. pre-assembly of side mirrors with electronic assistants). In such cases, we equip the pre-assembly stations with high-quality measuring equipment and test systems. Determined measured values are stored according to the regulations (long-term backup). LUCA systems offer many possibilities to design these workplaces and to combine them with different picking solutions.

Read also information about picking.