Pick by Light Prevents Searching for Components and Increases Quality

Grolleau SA is a company specializing in the design and manufacture of power distribution cabinets. The high reliability and innovation of its products give the company a leading position in the French market. At Grolleau SA, various cables and electrotechnical components are assembled and wired into different control cabinets. The large number of components must be located in the respective storage bins using the part number before assembly, which takes up valuable time. Since certain components look visually similar, the risk of confusion is also very high.

Grolleau SA wanted an assembly process that eliminated the time-consuming search for components. In addition, electric screwdrivers should be used in the future to ensure each component is screwed with the correct torque. Assembly and work instructions should be quickly retrievable and digitally available for each cabinet.

Due to the large number of cables and components stored on shelves, as well as the size of the cabinets, Grolleau SA chose an assembly line production concept. To achieve this, Grolleau SA relied on the SETAGO Pick-to-Light system and its associated software.

A scanner connected to the software reads the production order into the system. The system then guides the employee step by step, indicating which component is to be assembled.

The Pick-to-Light sensor on the shelf highlights the correct component, eliminating the need to search for and preventing mix-ups.

The software also transmits the correct torque setting to the integrated electric screwdriver for each specific work step, ensuring process-safe assembly. Once the component has been assembled, the employee moves on to the next work step.

Each step is displayed by the software with text, images, or video instructions. Together with Grolleau SA, the SETAGO Pick-to-Light system was set up, sensors were positioned, software was programmed, and training was completed.

Grolleau SA can now operate the system independently, including reading in or adapting new work instructions. Within one working day, the assembly line was fully operational, and personnel were trained.

Thanks to the consistent implementation of LEAN production, significant space savings were achieved, and the number of assembly workbenches was reduced from three to one assembly line. As a result, productivity increased by up to 15% per product.

Scope of delivery PM: 2 SETAGO systems with a scanner and approximately 150 sensors IO module for connecting external devices such as a scanner, screwdriver, and probe enclosure.