Operations that rely on manual order picking can often be met with ongoing challenges around speed, efficiency, and accuracy. As order volume increases and SKU counts grow, even small mistakes can lead to delays, returns, and added costs, especially during peak seasons. While human error is inevitable, the right material handling system can reduce these risks.
Pick-to-light systems are solutions that speed up the picking process by using visual cues to guide workers to the correct items and accurate quantities. See how these automation solutions are beneficial for operations and how one could integrate into your facility.
General Questions About Pick-to-Light
What is a pick-to-light system?
A pick-to-light system is an automation solution that uses colored lights to direct warehouse workers to items and quantity, making the picking process more efficient and accurate.
How does a pick-to-light system work?
A pick-to-light system uses highly-visible, colored lights to signal to workers where to find each item on their pick list. A digital display next to the light indicates how many items are needed. Once picked, a worker can press a button or scan a barcode to update inventory in the ERP/WMS. The system is also useful for replenishment activities.
What are the components of a pick-to-light system?
The components of a pick-to-light system include lighting terminals, screens affixed to each terminal, buttons at each terminal, and software to connect to ERPs or WMSs and Barcode Scanners.
Benefits & Performance Questions About Pick-to-Light
What are the benefits of pick-to-light systems?
The benefits of a pick-to-light system include increased efficiency and accuracy within the picking process. Here are some benefits:
- -Workers can find items quicker so less time is wasted searching.
- -Pick-to-light has a 99.5% accuracy rate.
- -The system is easy to use and workers can be trained in less than an hour.
- -Pick-to-light is integrated with your WMS, ERP, or other management system and updates inventory in real time.
- -Relative to other software or hardware automation solutions, Pick-to-Light is one the least intrusive or disruptive process improvements to install, as it can usually be installed easily on existing racking
How does pick-to-light improve accuracy?
Pick-to-light improves accuracy by showing the worker where each item is located, making it easier to pick the correct item. This system also tells the picker or replenisher how many of each item is needed, allowing for a clear visual of what they need to do. If they miss an item or the wrong quantity is picked, the lights offer a visual cue to alert workers of the mistake.
How much faster is pick-to-light compared to manual picking?
Pick-to-light can be much faster compared to manual picking. With this automation solution, workers aren’t wasting time searching for the items, instead there is a visual of exactly where their picking path is.
Once a worker scans a barcode to input an order, the software will locate each item in the order. An indicator light switched on at each item’s location, and quantities are noted in a digital display. Once the item is picked, a worker will press a button or scan a barcode to indicate it has been picked. Inventory is automatically adjusted in the WMS and the light switches off.
How does pick-to-light improve warehouse efficiency?
Pick-to-light improves warehouse efficiency as it speeds up the picking process and improves accuracy. With a 99.5% accuracy rate, there is less downtime wasted on mistakes and errors, ensuring an efficient operational flow.
Investment of a Pick-to-Light
Is pick-to-light worth the investment?
Pick-to-light is worth the investment for facilities with high manual order picking (>50 orders per hour depending on lines per order) that can improve their picking operations. This material handling solution has an immediate impact on your operations and can reduce time and money wasted on errors.
Use Case Questions for Pick-to-Light
Is pick-to-light good for parts picking?
Yes, pick-to-light is good for parts picking as it can speed up the process and decrease mistakes in the picking process. Facilities that have high pick volumes or use temporary workers for picking can especially benefit from this automation solution as it is quick to learn and adds efficiency to operations immediately.
What industries use pick-to-light systems?
Industries that use pick-to-light systems include, but are not limited to:
- -E-Commerce and Retail
- -Manufacturing
- -Warehousing and Distribution
- -Automotive
- -Pharmaceutical
Implementation Questions
How do you implement a pick-to-light system?
Implementing a pick-to-light system includes using hardware, software, and layout planning. Before implementing a pick-to-light, it’s important to assess your operations and design the layout of your picking path. Once that is in place, you’ll need to install the light modules for the pick-to-light which usually can be affixed to existing racking. Then, your new system can integrate with your software, and it’ll be ready for your employees to be trained on. Often times, a pick-to-light system on racking or shelving is paired with mobile put-to-light carts so that orders can be batch picked with speed and accuracy.
How long does it take to install pick-to-light?
The installation of a pick-to-light depends on the size of your system, but it is relatively quick and disruption to your operations is minimized. Installation can depend on the size of the picking area, number of light modules, and integration requirements.
Can pick-to-light integrate with a WMS or ERP?
Yes, pick-to-light must integrate with a WMS or ERP. This connection allows the system to receive your order data, track picking progress in real time, and update inventory after each pick.
Is pick-to-light hard to install?
Pick-to-light is generally simple to install but does require planning. It’s important to consider where you will install your system, whether that be on an existing rack or new setup.
Can pick-to-light be added to existing shelving or racking?
Yes, pick-to-light can be added to existing shelving and can be mounted directly onto shelving units, carton flow racks, bin systems, or workstations.
Operational Questions
How accurate are pick-to-light systems?
Pick-to-light systems have a 99.5% accuracy rate. These systems allow workers a visual for each step and also require confirmation. With a light at each item’s location, displays showing the correct quantity, and confirmation buttons, the guesswork is taken out of this process.
Can multiple workers use pick-to-light at the same time?
Yes, multiple workers can use pick-to-light at the same time. Each worker will follow their own set of instructions, which means workers can pick different orders in the same zone.
How does pick-to-light handle multiple orders?
Pick-to-light systems can handle multiple orders by using software to coordinate picking tasks in real time, allowing workers to handle several orders at once. Instead of treating orders separately, the system can receive multiple orders from the WMS or ERP and activate lights at all relevant pick locations.
Does pick-to-light work for batch picking?
Yes, pick-to-light works well for batch picking and is often used in these environments. Batch picking involves collecting items for multiple orders at the same time, and pick-to-light systems help with this by illuminating all required pick locations, guiding workers through a route, and reducing repeated trips to the same locations. When batch picking makes sense for a customer, a pick-to-light system on racking or shelving is paired with mobile put-to-light carts that hold typically 6, 9, or 12 order bins to be picked simultaneously.
Training & Workforce Questions
Is pick-to-light easy to learn?
Yes, pick-to-light is easy to learn. The system works on visual cues, indicating where to go and how many items to pick. The process is very intuitive and is widely used in fast-paced environments.
How long does it take to train employees on pick-to-light?
Typically, it takes employees less than an hour to be trained on pick-to-light. This system removes any need to memorize SKU locations, interpret picking lists, allowing workers to skip the long training sessions.
Does pick-to-light reduce training time?
Yes, pick-to-light significantly reduces training time. It does this by removing the need to learn warehouse layouts, removing reliance on pick lists, and has a short onboarding.
Other Questions
What’s the fastest way to manually pick orders in a warehouse?
The fastest way to pick orders in a warehouse is by implementing a system such as a pick-to-light combined with an optimized pick module layout. These systems eliminate time spent searching for items, using lights to guide workers to the right location, and show quantities instantly.
How can I reduce picking errors in my warehouse?
Reducing picking errors in your warehouse can happen by using pick-to-light systems to direct workers, display the exact quantity at each pick location, and require confirmation with each pick. Inventory should also be organized with proper labeling to reduce errors.
What is the most efficient order picking method?
The most efficient order picking method is a combination of a pick-to-light and a well-designed warehouse layout. This helps with high-volume operations and high-SKU environments.
How do warehouses improve picking accuracy?
Warehouses improve picking accuracy by using a combination of technology and process design. Common strategies include implementing pick-to-light systems for visual guidance, and organizing inventory for easy identification.
What automation is best for order picking?
The best automation for order picking depends on your operations and flow, but pick-to-light is one of the most effective automation solutions for this. This automation solution is ideal when orders are picked by hand, when there are multiple SKUs, and speed is critical.
Learn More About Pick-to-Light Automation Solutions
Do you want to know more about how pick-to-light could integrate into your operations? Chat with your St. Louis automotive expert at 833-754-2164 or fill out a form here, and someone will get back to you!
About the Author
John Fontaine
Automation Sales Lead
After a 9 year career as an officer in the US Navy Submarine Force, John developed vital experience in the advanced manufacturing and unmanned systems with business development roles at two major defense contractors. In directing the growth of ISS Material Shelving, a division of Industrial Shelving Systems, John’s mission is clear: to remain thoroughly customer-focused, ensuring that businesses who partner with ISS Material Handling seize the right opportunities for automation adoption, fueling responsible growth amidst challenging economic circumstances. When not in the office, John enjoys all things music, cooking, and fitness.