The production lines of the Automotive industry determine the pace in the warehouse. The quality of the replenishment processes, the order picking and the timely delivery to the line is the primary goal of the 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 brought to the line with a tugger train to match the cycle. External service providers often take over these tasks.

Poka Yoke in Automotive

Various methods have been developed worldwide to ensure the quality of different work processes. One of the leading philosophies on the issue 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 Pickingetc.) the appropriate processes with error avoidance according to the Poka Yoke principle (continue on Wikipedia).

Shopping cart (KIT)

The formation of a shopping basket 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 basket (KIT) and then to place the finished shopping basket according to the position in the line sequence. There must be no picking with shortages. Today, single-order picking is still often done with a slip of paper. In order to increase the quality of picking and to support the employees, various 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 is worked out in workshops and possibly tested in pilot facilities.

Multi-sequence picking (RACK)

Small and large parts are picked directly into the compartments of a sequencing trolley (RACK). In a RACK, parts for N vehicles are sorted into N compartments. In route-optimised 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. In order to ensure quality when using paper lists, it is often switched to a single-seqeunce method in SuMa (tray by tray). With this LUCA system, however, very high time losses occur due to repetitive walkways. With frequently changing staff, additional sequencing errors cannot be avoided.

The picking of RACKs with an optimal multi-sequence picking method should definitely 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, after picking, the warehouse staff carry out 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, organisation 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. Measured values are stored in accordance with the regulations (long-term backup). LUCA systems offer many possibilities for designing these workstations and combining them with different picking solutions.

Read also information about picking.