Why are paperless picking systems so special and what are the error rates? What distinguishes the system from other processes? How is a modern pick-to-light constructed? Where is it best used? Are there other picking systems? A Pick-to-Light system is one of the best picking systems, modular and very flexible. Mounting the displays at each picking location is easy and the subsequent conversion options are uncomplicated.
Shelves or mobile constructions are ideal for this purpose. The functions are clearly structured and the light signals are unambiguous. The system supports various devices such as barcode scanners, RFID readers, scales, etc. Almost all displays are equipped with several additional keys to correct errors plus, minus and F-key for special functions. Some displays have only a simple signal lamp and acknowledgement button.
You can find more details in the article: Pick-to-Light System. The system is controlled by the LUCA software in real time. The connection to the warehouse management system, material flow and conveyor technology is made via the LUCA-Server, which controls the entire processes. The pick-to-light sensor has an important new function in the removal confirmation. A sensor can be optionally installed above or below the compartment display. The sensor monitors the accesses and automatically confirms the activities.
However, the goods to be picked cannot be counted with it. The automatic access control is based on modern TOF light sensors. The mounting of the sensors must be precisely coordinated. The sensor as a light sensor can measure cm without a reflection mirror.
With a mirror, the sensor can even be used at cm. The pick-to-light system is very versatile as a picking method, supports the picker and avoids picking errors. The field of application is large. You can find out more details in the article: Where is Pick-to-Light used? Like all paperless picking processes, the Pick-to-Light process is based on a pick list with picking orders.
The data is transmitted by the warehouse management system and distributed to the appropriate picking areas. There are many variants of the mode of operation. The pick-to-light process is the term used to describe the individual work steps. The optimal picking processes are very important for a picker, his performance and quality. The picker should be guided safely and quickly to his storage location with the help of the compartment displays and confirm the pick with the acknowledgement button.
Picking errors must be reduced to an absolute minimum. In order to design the picking processes correctly, you have to pay attention to some details. The requirements for optimal access to a storage compartment are very different in the solution.
The picker should quickly follow the light signal at the storage location, clearly read the quantities on the quantity display and safely perform the confirmation short learning time and search time. The pick list does not exist and the order picker has his hands free. This is a great advantage of this picking system. The quantities to be picked should be calculated by the WMS in such a way that quantity corrections are no longer necessary.
The aim is to minimise the error rate and to speed up the picking process and picking processes. Very often, however, the requirements for the system are very specific.
We integrate different solutions and also build the process customer-specific. How can the correct orders be started? Can the completeness of the last order also be checked? Basically, there are two different start methods here:. If the receipts, cartons or containers are marked with a barcode 1D or 2D , stationary or mobile scanners can be used in the Pick-to-Light process scan.
In this case, the displays can also be activated via the delivery note or invoice. RFID technology is also supported. In the sequence , the process usually starts automatically, either from a data buffer or by automatically discharging the containers via a conveyor system. In both cases, the LUCA-Server monitors the individual operations and ensures the appropriate quality. In some solutions, the start of the next job is only possible when the previous job is completely finished.
Should an error occur here, the system generates an error message. On the other hand, pick to light systems have some disadvantages: Throughput and scalability — Most light-directed systems can have only one person in a work zone at a time, which reduces potential throughput. In addition, since the lights are wired to the shelving location, it can be expensive and time consuming to expand or modify a pick to light system.
Item count accuracy — Because pickers simply press a light to confirm their pick, they are not required to positively acknowledge or confirm the number of items they are picking.
Item verification — Pickers have no way to know if the correct item is in the pick location. Comparing Voice and Light-Directed Work Execution Solutions Pick to light solutions are intended primarily to address the productivity shortcomings of scanning and paper-based systems. Versatility : PTL is best suited for processes where products are small and pick-faces are dense, but they are less cost-effective in other applications. Voice picking systems can support multiple picking styles and virtually any other warehouse task, which improves labor flexibility and accelerates cross-training Speed and accuracy : Light systems place an emphasis on speed but accuracy may suffer in comparison to voice- or scan-based solutions where additional checks are built in.
Light systems offer no means to verify the products in a pick location, or to communicate to users pack factors or other heads-up messages. Real-time data capture : Manual data entry may be required to capture exceptions damage, wrong item in slot, etc. Comprehensive labor reporting : Pick to light systems provide simple productivity reporting based on user interactions with the lights. RF and voice systems each provide richer activity data for workforce and labor management purposes.
Cost : PTL systems typically require a large initial capital investment and high long-term maintenance costs. Adding new locations requires you to add more equipment, unlike voice where the system is not tied to the physical locations. They are also useful in medium and low-rotation environments, where more open solutions can be enabled or combined with radio-frequency systems. Our Pick To Light systems provide multi-colour options across their entire product range.
This, combined with easy programming, allows applications to be developed where several operators can work on picking the same order, or where a single operator can pick several orders simultaneously. It increases the number of orders per day, reducing the operational cost of order picking processes. Pick To Light Systems.
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