Pick to light: What it is, how it works and practical examples

Order preparation in warehouses is a task fraught with challenges, especially in high-demand environments with tight deadlines. To tackle these challenges and optimise processes, many companies are adopting advanced technological solutions. One of the most innovative systems in this area is Pick to Light. This system uses lights and displays to guide operators through product selection, enabling faster and more accurate picking.

The Pick to Light system excels in minimising unnecessary movements and streamlining workflows. By eliminating the need for picking lists and simplifying product identification, it revolutionises manual picking operations. With shelves equipped with Pick to Light technology, warehouses can enhance productivity while improving customer satisfaction by reducing delivery times.

In this article, we delve into what the Pick to Light system is, how it works, and practical examples that demonstrate its potential to transform warehouse management and optimise logistics processes.

What is the Pick to Light System?

Pick to Light is an advanced order preparation system designed to optimise the picking process in warehouses. It leverages dynamic shelves equipped with numeric displays and indicator lights, enabling operators to quickly and accurately locate items and select the exact quantity required.

How Does Pick to Light Work?

The Pick to Light system operates efficiently and intuitively:

1. Dynamic Shelves and Displays: Each shelf channel is equipped with a numeric display featuring buttons.
2. Integration with WMS: The displays are controlled by a Warehouse Management System (WMS) that manages and programs orders.
3. Guided Picking: When a new order is generated, the WMS activates the corresponding display, illuminating the exact location where the operator should pick items. The display also shows the precise quantity to be picked.
4. Confirmation: After picking the items, the operator confirms the action by pressing a button on the display. This turns off the light and updates the WMS, marking the task as complete and preparing for the next order.

Applications and Key Benefits of Pick to Light

Pick to Light is particularly effective in high-workload environments where speed and accuracy are critical. It is ideal for managing high-turnover goods and logistics processes requiring agile and efficient shipping. The system is versatile and can adapt to various workflows:

• Multi-Order Picking: Allows multiple operators to work simultaneously, with different lights assigned to each user for maximum efficiency.
• Zone Picking: Operators are assigned specific zones, eliminating unnecessary movement and optimising space and device usage.
• Integration with Automated Systems: Can complement automation solutions like mini-loads or roller conveyors to streamline merchandise transport further.
• Cart-Based Picking: Operators use carts equipped with lights to facilitate product collection, enhancing warehouse logistics.

Additional Advantages:

• Time and Error Reduction: Operators know exactly where each product is, saving time and minimising mistakes.
• Real-Time Inventory Updates: Stock movements are transmitted to the WMS for automatic database updates.
• Customer Satisfaction: Faster and more accurate order fulfilment leads to improved customer experiences.

Examples of Pick to Light in Action

Here are some examples of how Pick to Light has optimised operations across different industries:

1. Warehouses

In a large distribution warehouse, Pick to Light helps streamline order preparation for high-turnover products. Operators can simultaneously handle orders for multiple stores as illuminated shelves indicate which products to pick and in what quantities. This reduces preparation times and boosts accuracy.

2. E-commerce Fulfillment Centres

E-commerce giants like Amazon use Pick to Light systems in their fulfilment centres. When online orders arrive, numeric displays guide operators to dense shelving units, indicating items to pick and their quantities. This ensures speedy and precise order preparation, enhancing customer satisfaction.

3. Automated Logistics

Combining Pick to Light with automated systems like conveyors or Automated Guided Vehicles (AGVs) enhances logistics further. Lights guide operators during product picking, while AGVs transport the collected items to packaging zones, creating a seamless workflow.

Considering Pick to Light for Your Warehouse?

If you’re thinking of implementing Pick to Light technology in your warehouse and require professional guidance, Grupo SIM is here to help. Contact us today, and let’s optimise your logistics processes together!