Pick-to-Light System for the Car Seat Cover Production Line

+40 752 296 086

+40 753 104 251

+40 753 104 252

idustrial@automatix.com

Intro:

We developed and implemented a fully automated Pick-to-Light system for a car seat cover manufacturing plant, with the goal of streamlining workflows and increasing operator productivity.

Project Description

In the production process, each seat cover is assembled from multiple textile components and accessories, stored in separate bins. Our system allows the operator to work quickly and without errors: when the barcode of the seat cover is scanned, an LED lights up automatically above the bin containing the required component for that specific step.

After the part is picked and sewn, the next bin lights up automatically, guiding the operator step by step until the product is fully assembled.

This approach makes the workflow fast, intuitive, and error-free, eliminating downtime and the risk of selecting incorrect components.

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Key Features

Automatic component identification through barcode scanning
Visual indication using intelligent LED modules (Pick-to-Light)
Interactive HMI for configuring, adding, or modifying seat cover types
Password-protected access for authorized operators only
Real-time process monitoring with fault and alert display
Integrated safety systems – sensors, emergency stop buttons, audible and visual warnings

This set of features ensures a fast, intuitive, and fully controlled workflow, offering operators a high level of precision and efficiency.

Complete Implementation

Fully engineered and implemented by our team – electrical panel, wiring, sensors, HMI, PLC, and software
Seamless integration of hardware and software for optimal performance
Recipe management modules for saving, editing, and quickly loading new seat cover models directly from the HMI

The result is a robust and perfectly tailored solution, designed to adapt and evolve alongside the client's production line requirements.

Benefits and Results

By implementing this Pick-to-Light system, the factory achieved:

Significant reduction in production time and over 30% increase in workflow efficiency
Elimination of human errors in component selection• Improved traceability and process control
Easier training for new operators thanks to visual guidance
High flexibility – new product models can be added at any time

A smart, reliable, and scalable system that optimizes every stage of the assembly process, transforming a manual workflow into a digitalized, fast, and error-free operation.This project showcases our expertise in custom automation and our ability to bring Industry 4.0 technology into modern production lines.