Automotive
The production lines in the Automotive set the pace in the warehouse. The top priority for intralogistics is ensuring high-quality replenishment processes, order picking, and timely delivery to the line. The system must also guarantee the smooth supply of standard parts to the line. With a high degree of variety, sequencing in the warehouse must be guaranteed with 100% reliability. Sequence trolleys and shopping baskets are formed and placed on the line with a tugger train in line with the cycle. These tasks are often performed by external service providers.
Poka Yoke in Automotive
Various methods have been developed worldwide to ensure the quality of different work processes. One of the leading philosophies in this area was developed in Japan by Shigeo Shingo between 1961 and 1964. Today, work processes are planned and implemented according to the poka-yoke principle. LUCA systems support this with many picking systems and combinations thereof (pick by light, pick-by-frame®, pick-by-point®, Voice Picking, etc.) support the appropriate processes with error prevention according to the Poka Yoke principle (more on Wikipedia).
Shopping cart (KIT)
Depending on the model variant, the formation of a shopping cart in Automotive KLT or special box) usually takes place in a "supermarket" (SuMa). The parts are stored in different variants in the storage area. The task is to pick the appropriate parts into the shopping cart (KIT) and then place the finished shopping cart in the correct position in the line sequence. There must be no picking with short quantities. Today, single-order picking is often still carried out using a slip of paper. Various LUCA systems are available to improve the quality of picking and support employees: Pick-by-Scan, Pick-by-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 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. With route-optimized sequencing, several parts are often removed from a storage compartment at the same time and placed in different destination compartments in the RACK. Paper lists are not well suited for this process in Automotive. To ensure quality when using paper lists, a single-sequence method (compartment by compartment) is often used in SuMa. However, this LUCA system results in significant time losses due to repetitive walking distances. With frequently changing personnel, additional sequencing errors are unavoidable.
The picking of racks using the optimal multi-sequence picking method must be supported by technology. Various solutions are available for this purpose, in particular: Pick-by-Frame®. This highly efficient, high-quality method is very well suited for this application.
Pre-assembly
In some cases, warehouse staff perform various assembly tasks on the components after picking. These are then delivered to the lines in the correct sequence. For the Automotive, various solutions are available to support, organize, and manage system processes during assembly activities (pick-by-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 devices and testing systems. The measured values are stored in accordance with regulations (long-term storage). LUCA systems offer a wide range of options for designing these workstations and combining them with different picking solutions.
Read also information about order picking.
