Pick-to-Light Explained: Using Light for Direction

When distribution centres, manufacturers and logistics companies are looking to increase efficiency, shorten delivery cycles and reduce order-picking errors, the fastest operator-based solution is pick-to-light. It is easy to install and highly user-friendly, so pick-to-light can be implemented with very low disruption to day-to-day operations. Pick-to-light strategies can reduce labour requirements by up to 50% through improvements in productivity and accuracy, which is a significant advantage when tackling labour shortages.

What is Pick-to-Light?

Pick-to-Light is an order-picking system for use with split-case SKUs in warehouses or distribution centres. This system can also be adapted for manufacturing, kitting or assembling activities. 

Light modules are installed on shelving next to each SKU. These use light and LED displays to highlight the correct SKUs and the quantity required for an order. Effectively, Pick-to-Light removes reading from the order-picking process. Workers no longer need to read SKUs from a list and locate them on the shelves; they simply scan the order barcode and look for the lights. The easily visible lights also serve as a button for confirmation that the pick has been made.

By visually guiding picking, users can pick items with greater speed and accuracy than when reading from paper lists or displays. All of the important information is provided directly at the moment it is needed.

With this simple system, pick-to-light is easy to learn. Training takes very little time and order pickers can work quickly and accurately with a minimal learning curve. This is a huge benefit in distribution centres where temporary or seasonal staff are hired for this type of role, as they can get to grips with order picking quickly and maintain throughput and accuracy levels.

How Does Pick-to-Light Work?

Light-directed manual handling solutions are simple to install and easy to learn. Here’s some more detail on how pick-to-light works to remove points at which errors occur in picking activities. Lights and displays are attached to shelving next to each SKU and programmed with each product code. In the company’s internal system, each order is linked to a unique barcode, which is printed and placed in a tote, ready for picking. The totes are sent to the picking area, where order picking staff can begin the process.

1. Once logged in, the user scans the first order barcode.
2. The system illuminates the lights in front of the product and displays the quantity at the location.
3. The user goes to the illuminated location, picks the quantity shown and places the items in the correct order tote.
4. The user then presses the button to confirm, before moving on to any other illuminated items.
5. The order is complete, and the next order barcode is ready to scan.

The system also has an overhead bay display situated every 2-3 metres which shows the order status. It will show the order number, whether it is complete or ready to be passed to the next zone.

With Pick-to-light systems installed on shelving units, fulfilment centres servicing a highly varied SKU range can increase productivity and reduce picking errors. These systems are also useful in assembly situations, highlighting the parts required for a job.

Benefits of Pick-to-Light Solutions

When companies invest in pick-to-light, they can see an immediate change in throughput and accuracy. On average, switching to pick-to-light increases productivity by 40%, as the technology enables faster order picking compared to other, similar methods.

The advantages of our Pick-to-Light solution include:

• 99.9% accuracy once programmed
• Easy integration with host systems including WMS, WES, WECS 
• Analytics software, showing real-time graphical productivity and status information with a customisable user dashboard
• Flexibility and functionality developed through years of iteration and technological advancement
• Affordable and user-friendly
• Lightweight and easily transported

Is Pick-to-Light Right for Your Business?

Choosing the right order-picking technology for an individual business is challenging. As automation consultants, we are happy to advise companies on the types of solutions that will be appropriate and beneficial for the challenges they face. Here are some of the outcomes Pick-to-Light is proven to achieve.

Reduce Worker Fatigue

When facing high volumes of orders and a large variety of products, reading from an order list can be tiring. This fatigue amongst workers often leads to slowing down and errors in picking, particularly when facilities are low on staff.

With a digitised, light-directed system, workers can simply focus on the process without needing to read and search for the right SKU. This decreases the risk of mental fatigue, saving time and effort as well as increasing accuracy.

Pick-to-light can also be used in tandem with zone-picking strategies, reducing the distances workers need to walk to fill each order.

Integrate Existing Technologies

Our Pick-to-light can seamlessly integrate with most peripheral devices that are already in place, such as barcode scanners and ring scanners. This keeps the initial investment cost low, so small businesses are also able to adopt pick-to-light strategies for fast, accurate order filling.

Fix Bottlenecks

When demand is high, conventional order picking is a common crunch point for distribution and order fulfilment, creating a bottleneck which slows down throughput. While hiring additional staff can have an impact on these slowdowns, pick-to-light is a more cost-effective solution, allowing your existing team to work more quickly and accurately than before.

As a remedy to bottlenecks in order fulfilment, pick-to-light can help your facility accommodate any level of demand. This system is proven to improve material flow and, when used in conjunction with zoning strategies, can balance the workload between all pickers.

Pick-to-Light Implementation Support

With Guidance Automation, we can guide you through the process of identifying and implementing digital solutions in your business that will increase throughput and help keep you competitive in an increasingly automated market. Industry 4.0 solutions don’t require a huge shift in day-to-day operations or large scale investments. We provide easy access and implementation for pick-to-light systems in the UK, at rates affordable for small and medium-sized businesses.