LEAN assembly workstation with pick to light assembly guidance system

SETAGO Pick to Light – The assembly guide system

Sensor housing in plastic injection molding and translucent cover

Success Story

Starting point:

A “digital assembly manual” is intended to guide the employee step by step through the assembly process.
This is achieved with the Pick to Light assembly guide system. A light shows the employee which component to remove and install next. For process-reliable assembly and higher productivity with zero errors. The assistance system can be integrated into existing workstations and is child’s play to program thanks to the intuitive software.


Our task was to develop a housing in plastic injection moulding for the sensor and the LED with the following characteristics:

  • sleek and compact design
  • easy to mount at the workstation
  • mountable on round tube and 4-sided profiles
  • addressable from the outside
  • diffuse light distribution on translucent front


From more than 15 different design studies, 4 variants were selected, which underwent initial functional testing through Rapid Prototyping and served as an illustrative model.
The fastening of the sensor housing to the various pipes or strips at the assembly workstation was solved with an adapter plate which is snapped onto the plastic housing. The adapter plate can be screwed to the workstation or fastened with cable ties or by magnets.
The biggest challenge for us was distributing the light from the LED on the translucent front. We field-tested various materials and forms of the superstructure in different environments. It was important to us that the light is eye-catching but does not disturb or hinder the employee in his daily work at the workplace. After the feedback and evaluation from the field tests, it went into toolmaking and then into series production. In the end, each housing received a 2-colour pad printing.

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Send us a sketch or STEP file for a price enquiry.

Picture Mihajlo Maksimovic

Mihajlo Maksimovic

Project Manager

Tel. +41 52 742 75 13
Mail mihajlo.maksimovic@phoenix-mecano.ch