Picking
eKanban
Locationing
Consulting
At WITTENSTEIN, we have combined picking, eKanban and locationing in a continuous process — with the goal: 0 errors during installation and maximum transparency on the shop floor.
1 Starting position
In transmission assembly at WITTENSTEIN, paper-based picking processes, manual material supplies and a lack of feedback led to errors and increased costs. The aim was a paperless, fully digitalized solution for controlling the flow of materials — with the aim of enabling zero-defect production.
2 Approach
Together with the WITTENSTEIN project team and a factory planner (fastplan), we analysed processes on site, identified critical process points and developed a tailor-made overall concept. On this basis, hardware (ESLs, scanners & trackers) was selected, workflows were digitized and the solution was gradually introduced into operation — always in close coordination with the customer.
3 Implementation & Outcome
The solution combines pick-to-light with ESLs, an integrated eKanban system and location tracking for full process control. Employees receive visual guidance, automated feedback and work completely paperless. The result: a stable, efficient and error-free material flow enables the implementation of a 0-fault strategy in transmission production.
Error rate reduced to 0%
Rework costs -90%
Process lead time -20%
Employee satisfaction (according to survey) +87%
Scalability: The solution is currently being transferred to other areas and locations
Personal customer feedback
Thanks to ekko, we were finally able to digitalize our processes consistently. Mistakes are almost impossible today — and the team works more relaxed and efficient.
Digitalization Project Manager, WITTENSTEIN SE
