Automotive

The production lines of the Automotiveindustry determine the cycle in the warehouse. The quality of the replenishment processes, picking and timely delivery to the line is the primary goal of intra-logistics. The system must also guarantee the smooth supply of standard parts to the line. With a high number of variants, sequencing in the warehouse must be guaranteed with 100% reliability. Sequence carts and shopping baskets are formed and placed on the line according to the takt with route train. Often external service providers take over these tasks.

Poka Yoke in Automotive

Various methods have been developed worldwide to ensure the quality of various work processes. One of the leading philosophies on the subject 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 supports the system with many picking methods and their combinations (Pick-to-Light Pick-by-Frame®, Pick-by-Point®, Voice Picking, etc) the appropriate processes with error avoidance according to the Poka Yoke principle (further on Wikipedia)

Shopping cart (KIT)

The creation of a shopping basket in Automotive (KLT or special box) usually takes place 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 matching parts into the shopping basket (KIT) and then to place the finished shopping basket matching the position in the line sequence. There must not be a picking with a short quantity. In this case, single order picking is still often used today. Various systems are available to increase the quality of picking and to support the employees: Pick-by-Scan, Pick-to-Light (multi-user), Voice Picking, 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)

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 taken 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 Automotivearea. In order to ensure the quality when using paper lists, SuMa often switches to a single-sequence method (compartment by compartment). In this system, however, very large amounts of time are lost due to repetitive process routes. With frequently changing personnel, additional sequencing errors cannot be avoided.

The picking of the RACKs with optimal multi-sequence picking methods should be supported technically. Various solutions are available for this, above all: Pick-by-Frame®. This very efficient and high quality method is very suitable for the application.

Pre-Assembling

In some cases, warehouse staff carry out various assembly operations of the components after picking. 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 contact us for more information.

Documentation for shoring

When pre-assembling technically sensitive components, the automotive industry often requires documentation of the installation (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. Measured values are stored in accordance with the regulations (long-term preservation). LUCA offers a wide range of options for designing these workstations and combining them with various picking solutions.