Before the fully automatic ILS system was introduced, employees had to manually search for the required seat covers in the warehouse and bring them to the various production stations. With short lead times, last-minute changes and call-off orders every few minutes for around 16,000 seat covers in the warehouse, this was a difficult task. Today, filtering, sequencing and transport to the workstation are carried out automatically by the system, which covers all areas of reference production at the Neuburg site: from incoming goods to dynamic storage and sorting to the workstations. Storage and sorting gyros allow quick access to every item in the system.

The ILS 2100 system has been in operation at Faurecia in Neuburg since September 2017. The intended optimization and cost effects quickly became apparent. Warehousing, picking, sequencing and delivery are managed by only one employee per shift. The room height and the available space are optimally utilized: The warehouse, sorter and buffer were built two stories up. The goods are transported up and back down via steep floor conveyors. The delivery of the covers to the workstations also takes place above the heads of the employees. This frees up valuable floor space. The new plant was built without any significant disruptions during ongoing operations. Their mechanics prove to be robust and low-maintenance; minor malfunctions are remedied in no time. Ergonomic workstations support and relieve employees. Thanks to seamless tracking of all items in the system, inventory management is always up to date. For quality checks, individual covers can be requested and checked. The error rate today is close to zero.