Automotive
What Is Automotive Warehouse Automation?
Automotive warehouse automation refers to the use of automated systems, software and intralogistics technologies to optimise production supply, sequencing processes (JIT/JIS) and spare parts logistics within automotive manufacturing and distribution environments.
Automated warehouse systems support material flow from incoming goods to storage, production supply and distribution. Technologies such as conveyor systems, automated storage and retrieval systems (ASRS), picking systems and warehouse software help automotive manufacturers improve process reliability, increase transparency and ensure efficient use of space and resources.
In highly dynamic automotive environments, warehouse automation helps manufacturers respond to fluctuating demand, complex production processes and increasing pressure for efficiency, traceability and delivery accuracy.
Technologies Used in Automotive Automation
Automation solutions in the automotive industry must support both production logistics and spare parts distribution. With tailored system design, these technologies can be adapted to manufacturing plants, warehouses and distribution centres.
Conveyor Systems
High-performance conveyor systems form the backbone of automotive intralogistics. They connect incoming goods, storage areas, production supply and shipping zones, ensuring reliable and predictable material flow.
Conveyor technology, such as transfer units, vertical conveyors, turntables and stackers, enables the efficient transport of containers, trays, cartons and pallets, supporting tightly synchronised production processes.
Automated Storage and Retrieval Systems
Automated storage and retrieval systems (ASRS), including shuttle, miniload and pallet solutions, enable high-density storage and fast access to components. These systems optimise space utilisation, prioritise fast-moving items and support accurate inventory management.
AS/RS solutions are particularly suited for spare parts logistics, buffer storage and production supply, where availability, speed and reliability are critical.
Workstations and Picking Robots
Picking robots and workstations play a central role in automotive spare parts logistics and kitting processes. Components are automatically delivered to the picking station, reducing walking distances, manual handling and error rates.
Picking robots and automated workstations support consistent quality and stable throughput, even with high SKU diversity and fluctuating demand. At the same time, they improve ergonomics and help address labour shortages in automotive intralogistics environments.
Warehouse Management Systems
Warehouse management and control software ensures transparency across automotive intralogistics processes. Real-time data enables the tracking of material flow, inventory levels and order status across production, supply and distribution operations.
Software solutions also provide the foundation for KPI monitoring, continuous improvement and integration with higher-level systems such as ERP and production planning tools.
Case Study: Cost Reduction Due to Optimisation of Operation Sequences
At Mercedes-Benz USA LLC, the task was to optimise parts distribution processes and reduce transport costs. A quantity-efficient order picking system was designed to connect the upstream and downstream functional areas via 2,350 m of high-performance conveyor technology. Through the successful project, the goals of process optimisation and transport cost reduction were optimally achieved. Additionally, we significantly improved the workplace conditions for the team members.
Case Study: An Innovative Automotive Logistics Centre at KW Automotive
At the chassis manufacturer KW automotive in Fichtenberg, Swabia, the task was to implement the entire intralogistics solution including automated warehouses and modern conveyor technology as well as a Pick-to-Light system (PTL) in the Built-to-Order production and to integrate it into a flexible production structure with network capabilities.
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