Pick-To-Light Systems

Although widely discussed in industry forums, Pick-to-Light can still be a confusing topic. Many people sense that the concept may be helpful to their operation, but are hesitant to investigate the technology. They are intimidated by the multitude of equipment options or are not sure how it can apply to their situation. This section is intended to describe Pick-to-Light in simple terms and offer suggestions for applying and implementing the technology. Pick-to-Light (P-T-L) is a series of lights or displays, mounted at picking locations that are used to direct order picking. P-T-L lights and displays can be mounted on shelving, flow rack, pallet rack, coolers, carousels – any stable stand or mounting surface. The lights are controlled by computerized software that is configured to meet the needs of a particular picking operation regardless of volume, the type of goods picked, or the number of pickers. In most cases, a PC will operate any P-T-L system efficiently. There is no limit to the number of lights for a P-T-L installation. There are systems in existence with as few as 50 lights and as many as 10,000. Light and display combinations can be of different styles depending on the given application in each area of operation.

Pick-to-Light Benefits

Pick-to-Light has the capability to greatly improve picking productivity and accuracy, especially for systems that run at high rates. In addition, some of the benefits of P-T-L include

• Paperless order picking. No printed pick lists or pull tickets.
• Eliminates the time and effort wasted on “looking around.”
• Workers can pick hands free.
• Allows computer-controlled picking.
• Can be applied to replenishment.
• Improved pick productivity and accuracy.

Pick-to-Light Components & Operation

A Pick-to-Light system is available to meet the needs of virtually any picking function, regardless of complexity or application. As these systems continue to proliferate, more features become available. Examples of typical Pick-to-Light system components, and the way they operate, are shown in the diagram on the following page. Check with a reputable vendor to determine what is currently offered and how it may be applied to your particular situation.

Pick-to-Light Selection Criteria

Pick-to-Light systems can greatly improve a picking operation, but represent a sizeable investment in time and capital. When determining if a P-T-L System is right for your warehouse, consider the following selection criteria,

• Project Scope. Examine each potential application and what you hope to gain by applying the technology, whether that is reduced labor, higher productivity, or some other benefit. Determine whether the system is site or application specific and if it is cost justified. Also determine whether P-T-L is appropriate versus other available technologies.
• Implementation Candidates. Some likely areas where Pick-to-Light can be considered are as follows
• Medium/high velocity, low-cost items.
• Low-volume, high-cost items.
• Cyclical or seasonal peaks.
• Minimized training in a high-turnover environment.
• Preliminary Steps. Once the requirements and objectives are clear, it is time to select vendors for pre-qualification. Make sure that you are comfortable with their capabilities and ethics. Award the work to the one that you feel will give you the best value – not just the lowest price. A system that does not work as intended is no bargain, no matter how attractive the initial price.

This is the area in which advances in technology have transformed the picking operation and improved accuracy and productivity significantly. The introduction of bar coding, voice technology and pick-by-light systems is not only improving warehouse picking operations but also producing an acceptable return on investment. The following picking methods are currently in use in today’s warehouses,

• paper pick lists
• pick by label
• pick by voice
• barcode scanning
• radio frequency identification
• pick by light/pick to light
• put to light
• automated picking