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Warehouse and distribution centres often seek easier and more powerful ways to process orders without leading to an increase in errors. As online consumers rise, so do their expectations, leaving behind traditional picking methods in favour of modern technology.
The introduction of systems, such as pick-to-light, helps to negate bottleneck issues and provide greater accuracy for staff and customers alike. This guide looks further into pick-to-light, understanding what it entails and how it continues to help businesses operate on a daily basis.
What Is a Pick-to-Light System?
A pick-to-light system is an order picking station that provides visual cues through illuminated displays. Rather than staff having to rely on hand scanning or following lists, they can be directed by lights positioned along shelving or racking bays, saving time when locating stock.
Once an order is ready to be picked, the light will illuminate to show its exact location. A digital display will then inform the operator of the required total amount to ensure the picker can source the item and its quantity correctly, before confirming the job is complete on the display.
How Does a Pick-to-Light System Work?
These types of systems are integrated with the internal Warehouse Management System (WMS) or specified inventory software. Once an order is received in the warehouse, the system will communicate with the hardware installed in each storage area.
Lights will then activate at each relevant pick face, guiding the individual through warehouse storage zones in one simple, fast approach. Once a picker completes the task and confirms the action, the system lights move to another location. The real-time communication between the system and management software helps to make sure orders are distributed on time, stock levels remain updated, and there’s greater visibility throughout the journey.
Where are Pick-to-Light Systems Most Effective?
Pick-to-light systems are ideally suited for facilities that have high order volumes, fast-moving stock, and repetitive picking tasks. These environments are important as they’re more subject to errors and backlog, eventually hindering profits. Pick-to-light systems are common within:
- Ecommerce fulfilment centres
- Retail distribution hubs
- Food and beverage warehouses
- Pharmaceutical and healthcare environments
- Assembly operations
For many businesses that handle light goods or SKU-heavy inventories, pick-to-light software removes layers of complexity for staff, helping to maintain performance, even during peak demand.
The Benefits of Pick-to-Light
One of the greatest advantages of pick-to-light systems is their ability to reduce picking errors, thanks to their visual guide. Removing written instructions is incredibly helpful for staff, as they’re less likely to suffer from fatigue, distractions, or misinterpretations.
In turn, this also benefits operational efficiency, with pickers having to spend far less time searching for stock or second-guessing the task at hand. The increased speed leads to reduced labour costs and the chance to give staff higher-value tasks throughout the day. Due to the intuitive nature of the system, time spent training is also greatly reduced, with new warehouse operatives becoming more productive at a faster rate.
Considerations Before Investing in Pick-to-Light
Before choosing a pick-to-light system, it’s important to assess whether your business operations are suitable for the technology. There are certain factors to consider, such as the order volume, SKU count, warehouse layout, and potential growth plans in the future.
Pick-to-light is most effective in zones with high pick rates, and many facilities are opting for a hybrid model between traditional methods and smart software. Working alongside an experienced storage and racking provider can ensure the right system is built to accommodate and enhance business workflow.
Integrating Pick-to-Light with the Right Storage System
A good pick-to-light system benefits from pairing with a well-designed racking or shelving solution. A clear pick face, streamlined product placement, and ergonomic movement are all major contributors towards smooth logistics.
Storage layout and safety are just as important as the software itself, since the pair go hand in hand. Opting for a poorly designed storage system can limit the benefits of an automated system, ultimately hindering performance and putting staff or stock at risk.
Invest in Smart Order Distribution with Prodek
At Prodek, we understand that order fulfilment begins with investing in safe and reliable infrastructure. Our approach combines intelligent software with robust and optimised storage solutions to enhance layouts and improve distribution.
We offer turnkey solutions, from full site assessments to installation and maintenance of a range of shelving and racking units, working closely with you to align business goals and outcomes. If you’re looking to improve picking workflow, speak to a member of our team today.
