Adient Seating UK Ltd

Pallet flow dynamics system

Design, development and installation of a pallet flow dynamics system for the storage of automotive seating materials at Adient Seating UK Ltd. The system was installed during a 2-week production stop and has optimised the company’s materials flow at its production facility based in Burton-on-Trent. Take a look at Phase 2 of the project.


Client Background:

Adient Seating UK Ltd is the market leader in the $70 billion, worldwide automotive seating industry. As an independent public company, they have the ability to reinvest in their core business and to quickly capitalize on emerging trends and innovations – in automotive seating and beyond.


Adient Seating UK Ltd



Burton-on-Trent, Staffordshire


Project Summary:

Design and installation of a pallet flow dynamics system for the storage of automotive seating components.

Dynamic pallet live storage system
Pallet live storage
Pallet live storage system 1 1

Enhanced picking speeds, product rotation and materials flow


Adient Seating UK Ltd has had to work with a poor materials flow at their production facility in Burton-on-Trent for some time, due to a bulk stacking method that was inconducive to their just-in-time materials flow. Even though the setup was managed very well by an experienced materials team, without automated stock rotation and a better picking strategy their best efforts were limited by the system at hand.

In 2017, Adient Seating UK Ltd invited SEC Storage to propose a solution to overcome this problem, which originally took the form of a mezzanine floor solution with integrated dynamics. However, due to customer demand where one model of vehicle was discontinued and replaced with a higher volume single model, this resulted in a reduction of different part numbers that Adient Seating UK Ltd had to manage. This increased the volume for each part number, and so a different solution was now required in order to fulfil future requirements.


Further operational analysis, completed after the introduction of the new model, enabled SEC Storage to develop a solution built on an adjustable pallet racking base, which would also include integrated dynamics in the form of a push-back system and pallet live beds installed within the racking lanes to enhance stock rotation and selectivity. 



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Pallet live roller system
Pallet live storage for automotive components
A semi automated solution - pallet live storage

Project installation completed in a 2-week time window


In a pallet live setup, the product is inserted into the higher end of the storage channel where it will then slide over the rollers at a controlled speed to the lower end to be extracted. This enables perfect product rotation via the FIFO (first-in-first-out) method, whilst also reducing the time spent at the pick face by the team's dedicated MHE operators.


As Adient Seating UK Ltd operates to a continuous day and night production schedule, SEC Storage was given only a 2-week window of opportunity to complete the installation. This was achieved via our installations team working to a tight schedule in order to minimise operational disruption to our client's production process.


Overall, this new dynamic storage solution has helped our client to greatly enhance their materials flow via the creation of dedicated and controlled stock locations. This installation is part of a larger, multi-phase project that will improve our client’s materials flow in various ways moving forward.




Interested to see how we've optimised other warehouse operations? View our case studies...

Warehouse racking sprinkler systems
Dynamic pallet live roller system
Warehouse sprinkler system

Before you go... Take a look at some of our other storage projects