Pick-to-Light Systems: Light-Directed Order Picking

Technology Overview

Pick-to-Light (also known as Pick-by-Light) is a mature and widely adopted light-directed picking technology designed to enhance manual order fulfillment operations. It serves as a crucial mechanization step between fully manual processes and higher levels of automation. By replacing paper lists or RF terminal screens with simple visual cues, the system streamlines the cognitive and physical tasks of picking, allowing operators to work faster and with fewer errors. For over 25 years, systems like Lightning Pick have established a strong user community, proving the technology's effectiveness in environments demanding both speed and accuracy for piece picking.

How It Works

Core Principles

The core principle is visual guidance to eliminate decision-making latency. The system uses lights and digital displays at storage locations to directly indicate the exact item and quantity to pick, removing the need for the operator to read, interpret, and remember instructions from a separate device.

Key Features & Capabilities

The visual guidance system is the defining feature, transforming picking from a cognitive search task into a simple follow-the-light action. This technology is particularly effective for zone picking, as it seamlessly divides an order across multiple workers, with system displays managing the handoff between zones. Modern systems offer advanced software with real-time visibility, giving supervisors dashboards for live monitoring of order progress, individual/team productivity, and system throughput. The evolution towards modular and low-power hardware makes the systems more flexible and easier to reconfigure as SKU locations or warehouse layouts change.

Advantages & Benefits

The most significant benefit is the substantial gain in productivity, with typical increases of 30% to 50% in throughput by eliminating time spent reading and interpreting pick instructions. This directly translates to lower labor costs per order. Equally important is the dramatic improvement in accuracy, as the system minimizes mis-picks caused by reading errors or incorrect quantity entry. The system also reduces training time and operator fatigue, as the process becomes more intuitive and less mentally taxing, leading to a better work environment and lower error rates.

Implementation Considerations

Successful implementation requires a thorough analysis of the existing process, SKU count, and order profile. The system is most effective in high-volume, multi-SKU environments with a high proportion of piece picks. Physical layout planning is needed to optimally position light modules and bay displays. Integration with the host WMS is essential for seamless order downloading and confirmation feedback. While the hardware is relatively straightforward, the software configuration and process design are critical to realizing the full productivity benefits.

Use Cases & Applications

Ideal For

This system is ideal for distribution centers, third-party logistics (3PL) providers, and manufacturing kitting operations that handle a high volume of small-item or "broken case" orders where picking speed and accuracy are bottlenecks.

Performance Metrics

The video content provides a key performance indicator: implementation typically leads to a 30 to 50 percent increase in productivity and throughput. Additional metrics are enabled by the software, which provides real-time data on order status, pick rates, and operator productivity, allowing for continuous measurement and improvement.

Conclusion

Pick-to-Light remains a highly cost-effective and reliable technology for optimizing manual picking operations. It offers a compelling return on investment by significantly boosting both the speed and accuracy of order fulfillment without the complexity and high capital cost of fully robotic systems. For operations with suitable order profiles looking to improve efficiency, reduce errors, and gain better operational visibility, implementing a Pick-to-Light system like Lightning Pick is a proven strategy to achieve immediate and sustainable gains.