Pick to Light Application: Optimizing Order Picking in Automotive & Motorcycle Manufacturing Plants

As part of its journey toward modernization and automation, an automotive–motorcycle manufacturing plant selected the Pick to Light solution implemented by ETEK. The system was deployed across 15 Kitting areas and 7 Sequencing areas, managing up to 3,575 components. This marked a major step forward in accelerating picking speed, reducing operational errors, and improving overall efficiency.

1. Project Overview

Facing growing production demand and the industry-wide shift toward digital transformation, the manufacturer sought a solution capable of efficiently handling a large volume of components at assembly points. Partnering with ETEK aimed to eliminate the limitations of manual picking while integrating the new system with the existing Manufacturing Execution System (MES), creating a seamless and highly accurate production flow.

2. Practical Challenges and Deployment Scale

Existing challenges:

• Manual picking processes were time-consuming, negatively impacting production schedules and productivity.
• Picking errors and component mix-ups affected final product quality.
• Data tracking and control were difficult due to manual verification and confirmation steps.

Current scale:

With such a large number of components, the key challenge was to implement a smart solution that could significantly improve both speed and accuracy in the picking process.

3. Customer Requirements

To address these issues, the customer defined several core requirements:

• Deploy Pick to Light in two critical areas: Kitting and Sequencing.
• Build mechanical and electrical infrastructure, including racks, conduits, signal lights, and LED display panels.
• Provide control equipment such as industrial PCs and servers for system operation.
• Integrate the new system with the existing production management software to ensure data synchronization.
• Train staff to independently operate the system and troubleshoot issues when needed.
  

4. ETEK’s Integrated Solution

ETEK delivered a comprehensive, end-to-end solution to fully meet customer needs:

• Design and implement an intelligent Pick to Light system in targeted areas.
• Install the complete mechanical and electrical system, ensuring durability and scalability.
• Seamlessly integrate with the MES for real-time data updates and management.
• Supply modern hardware and control infrastructure to support stable, continuous operation.
• Conduct in-depth training programs for the factory’s technical team.

5. Structured Implementation Process

From initial assessment to full operation, ETEK worked closely with the customer through the following steps:

1. Survey existing processes and analyze bottlenecks in picking operations.
2. Design the system and prepare detailed technical drawings.
3. Install Pick to Light modules and supporting equipment.
4. Integrate Pick to Light software with the existing production control system.
5. Test, fine-tune, and provide hands-on training for operators.

Thanks to thorough preparation and an experienced project team, the project was completed on schedule, delivering strong technical performance and tangible operational benefits.

Learn more about the Pick to Light system: Smart Pick to Light Solutions | Digital Picking System