Forklifts unload cargo carriers from the lorries and transfer them directly to tugger trains. The route layout for the tugger trains in the “Assembly supply centre” is organised a little differently than in the “Body supply centre.” Michael Weihrauch, Head of Logistics: “Depending on the contents of the containers, the tugger trains drive them to the pick-and-place and sequencing zones or to the supermarket for ‘kanban’ parts.” That sounds like a blend of purchasing centre and computing centre. And in principle, it is both. But what is really complex in terms of process flow – in a perfectly organised and understandable system that has a lead time of seven days – is how it is possible to use small, electrically powered “freight trains” to transport around 4,500 different parts of all sorts into the assembly areas of the Porsche plant in Leipzig, without making any errors and according to a reliable schedule.

From the supermarket to assembly. As described, the containers that are unloaded from the lorries are supplied to the pick-and-place and sequencing zones. The containers delivered by tugger train are placed in these yellow-framed areas, either on the container technology or on flow racks. In the middle, an aisle-way is open; this is where employees pass through with a pick-and-place or sequencing carts and get – via ‘pick-by-light’ – the information on the parts that are needed and must be gathered. The part shown by the ‘pick-by-light’ is removed and placed in the pick-and-place cart. The fully loaded carts are then placed in a zone marked for it – at the ‘train station.’ The tugger train driver, who shuttles parts between the assembly area and the supply centre, takes the pick-and-place carts from there and delivers them to the assembly line. The flow is very simple when the underlying logistical organisation is set up properly.