Automotive supplier hit zero-defect kitting with MileSoft Pick-to-Light + radar alignment

Each bin has a unique LED indicator and a physical lock. The system reads the current work order from the MES and lights exactly one bin per pick step. Other bins remain locked. The operator cannot open the wrong bin — the failure mode is physically eliminated, not training-dependent.

The bin is locked by a magnetic or mechanical locking mechanism controlled by the MileSoft runtime. It does not open. The system also logs the attempted access. If the operator forces the lock, a tamper event fires in the Andon dashboard and the kit is flagged for inspection before assembly continues.

After mounting, the radar module boots a sealed self-test against a fixed fiducial on the station. The module's own firmware measures azimuth, elevation, and roll, returning values to the MileSoft station. If any value is outside tolerance, the station locks the unit and raises an alert — the unit cannot proceed without an engineer override.

Pick-to-Light removes the need to memorise variant differences. New operators follow the lit bin — the system handles variant identification. Ramp-up time now covers station procedure, safety, and exception handling rather than part-number memorisation.

Every pick event, alignment result, and test result is logged with operator ID, timestamp, and unit serial. For an OEM line walk, the audit trail is available in the MileSoft dashboard filtered by date range and station — no manual log consolidation required.