Case study — automotive industry
Picking with an error rate of less than 0.0001%
How the Jaguar Land Rover manufacturing plant in Nitra accelerated material picking for production and almost eliminated errors — thanks to the M2L (Pick to Light) system from M2M Solutions.
0,0001 %
current picking error rate
450
withdrawals per hour per operator
30 – 150 %
productivity increase depending on the layout
DHL EXEL SLOVAKIA AT A GLANCE
Location Bratislava
Function Internal logistics in car production
Employees 1200
Systems in use M2L (Pick to Light)
Growing production, lack of people, pressure on quality
DHL is a global leader in the logistics market and offers a comprehensive portfolio of logistics and transport services through its four divisions. At the Bratislava car plant, it provides internal logistics — picking parts at commissioning workplaces exactly according to the production plan for a specific vehicle.
The constant increase in production, requirements for flexibility, lack of personnel and pressure to improve quality have presented DHL with a new challenge. When processing several cars at the same time, the need arose for more precise navigation, sequencing and control of parts picking. Manual management of these processes increased the risk of errors, slowed down the operation and made it difficult to have an overview of the status of individual positions.
The key became the need to simplify and speed up parts picking without having to change the existing shelves and large boxes at the workplace.
Are you dealing with the same thing at your workplace?
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Is picking material for production still based on paper records or does it require lengthy training?
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Operators have to find the right warehouse position for a specific order themselves and the error rate is difficult to keep under control?
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Do you need to pick multiple orders simultaneously, without the risk of material mix-ups?
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Training a new operator takes too long and personnel fluctuations threaten the pace of production?
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Do you want a solution integrated with SAP, not an isolated tool?
Good news: visual navigation works intuitively even for a completely new operator — training is a matter of minutes, not weeks.
Flexible solution for multiple orders at once
The system is designed as a highly flexible modular solution — it can pick multiple orders simultaneously and at the same time maintain double control of correctness when picking material. This guarantees timely and correct delivery of material to production exactly according to the end customer's order, while maximizing the use of workspace and minimizing downtime.
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Possibility of picking multiple orders simultaneously.
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Duplicate control of correctness of picking.
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Easy to operate, does not require lengthy training.
M2L - manipulate to light (Pick to Light)
Light beam instead of paper and searching
The system visually marks the warehouse position from which the material is to be picked for a specific order, and immediately displays the number of pieces that the operator is to pick. The selection is confirmed by simply interrupting the light beam — so-called free-hand picking — which speeds up the process to the pace of the set production cycle.
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Visual marking of the warehouse position for a specific order.
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Display of the exact number of pieces to be picked from the given position.
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Integration with SAP and third-party systems.
0,0001 %
current picking error rate
450
withdrawals per hour per operator
30 – 150 %
productivity increase depending on the layout
What did it bring to Jaguar Land Rover?
Measured in real operation of the production plant in Nitra.
Other operational improvements
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The ease of use has significantly facilitated the training of new operators and helps with unexpected personnel fluctuations.
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The quality of picking is maintained while minimizing the error rate.
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The system guarantees a smooth flow of material into production.
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Visual navigation provides comfort to operators, who are not overloaded despite the high work pace.
A new level of picking from M2M Solutions
Connection to SAP and third-party systems
M2L integrates directly into the existing SAP of the manufacturing plant — without the need to build a parallel information system.
A solution adapted to the layout of the operation
A productivity increase of 30 to 150% shows that the solution is not a universal template — the effect depends on how precisely the system is designed for a specific warehouse layout.
Easy training even with staff fluctuations
Visual navigation reduces training requirements so much that the plant can smoothly manage fluctuations in staffing without losing momentum.
Verified in the operation of a global automaker
The system is running in real production with a goal of 150,000 vehicles per year — this is not a semi-operational pilot, but a deployment with full responsibility for the flow of material into production.