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

Many methods have been developed worldwide to ensure the quality of various work processes. One of the leading philosophies in this field was developed in Japan by Shigeo Shingo from 1961 to 1964. According to the Poka Yoke principle many work processes are planned and implemented today. LUCA supports with many picking systems and their combinations (Pick-by-LightPick-by-Frame®, Pick-by-Point®, Pick-by-Voice, etc) the appropriate processes with error prevention according to the Poka Yoke principle (see Wikipedia).

Shopping Cart (KIT)

Depending on the model variant, the creation of a shopping basket in the (KLT Automotiveor special box) is usually done in a "supermarket" (SuMa). In the storage area all parts of the different variants are stored. 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 short quantities. 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-by-Light (multi-user), Pick-by-VoicePick-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, the employees in the warehouse carry out various small pre-assemblies of the components, which must then be delivered to the lines pre-assembled in a suitable sequence. Various solutions Automotiveare available to support the organisation and processes of the assembly activities (Pick-by-Light, Pick-by-Voice, Pick-by-Frame® , etc). Just contact us for further information.

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.