Boost Warehouse Efficiency: How Pick to Light Reduces Human Error

The pressures applied on warehouses and manufacturing facilities in the present supply chain fast-paced world include the absence of margins on accuracy, speed and general efficiency of their operations. The Pick to Light system is one of the breakthrough technologies garnering high attention since it is a digital solution that allows eliminating human error, enhancing productivity, and improving warehouse functions.

This blog discusses how pick to light technology can transform any warehouse and manufacturing unit and the working of pick to light system.

What is Pick to light Technology?

 Pick to Light is an automatic system of order picking, based on the indicator and the use of lights to show a warehouse worker where the exact location of the product is to pick an order. Rather than seeing to paper registers or hearing verbal commands, the operators merely move along to lighted racks or shelves and gain the right items with the correct number.

This system pours errors down and gives a significant boost to the picking process by limiting search and re-verification of the places where products could be found.

What Does a Pick to Light System Do?

 A typical pick to light system used in a warehouse is comprised of:

• Light indicators: These lights are placed on a rack, bin or shelf so they turn on to tell the operator where to pick.
• Displays: The number of items to be picked is displayed in numeric or alphanumeric display.
• Operator interface: Buttons or touch-panels are the means of providing confirmation of picks by the operator.
• Central controller/software: This guided the picking instructions, monitors the process and interfaces with Warehouse Management Systems (WMS).

Upon an order being received the system switches on the respective lights and displays that are to be attended by the picker. As soon as the operator has selected the needed number, he/she verifies it, and the system passes to the next pick.

Benefits of Pick to Light Systems in Warehouses

1.Minor Human Error by far

With the visual guidance that is provided to the operators, one can reduce operator errors including:

• Selecting an incorrect product/Incorrect amount
• Abandoned orders
• Misunderstanding of reading paper lists or hand held scanners

The resultant effect is better accuracy of orders and the reduction of returns and complaints by the customers.

2. Quicker Order API

Visual picking eliminates time wastage due to searching or confirmation of items since the operators can perform the picking process very quickly. It has been observed that pick to light technology has the capacity to boost the rate of picking up by up to 40 percent.

3. Less Time In Training

There is little training required to operate the pick to light system as new operators are able to utilize the system easily.

4. Better Worker Productivity and motivation

Making the task simpler and less demanding in terms of cognitive load makes workers more confident and less stressed, which enhances their morale in general.

5. Smooth Interaction with the Warehouse Management Systems

Current pick to light systems also work seamlessly with current WMS and ERP software so tracking and reporting is done in real time.

Manufacturing Pick to Light System

Pick to light systems have many advantages that go past the warehouse and into the manufacturing environment:

• Makes sure that the assembly lines have an accurate component selection
• Minimizes downtime resulting to shortage of parts or errors during picking.
• Improves quality control Verifies picks prior to assembly
• Supports Just-in-Time (JIT) production

The presence of pick to light technology improves control of the inventory, throughput, and scrap rates among manufacturers.

Why Choose a Pick to Light Warehouse System?

Most warehouses continue to use manual picking or barcode scanning that is time consuming and likely to become pinned. A conversion to a pick to light warehouse environment will bring benefits that include:

• Error correction and detection in real-time
• Multi-order pick functions
• When combined with voice or RFID systems, hands-free allowing use
• Ability to be flexible with shifting warehouse layout or SKU profile

Case Study Snapshot

Conclusion

Incorporation of pick to light technology is therefore a strategic investment move to warehouses and manufacturing plants interested in minimizing the element of human error and increasing the efficiency of operations. This system also saves a lot of time and cost in the picking process that results in fewer mistakes and ensures the workforce is productive.

Incorporating or improving to sophisticated picking systems can be revolutionary to businesses wishing to adopt a picking system, finding the right professionals in the business can also provide customized pick to light systems.

Find the latest in industry automation, such as the accolades installations of pick to light systems, at StacklOT, the provider of smart factory and warehouse solutions.

FAQs

1. Is pick to light technology expensive to implement?

Costs vary depending on system size and complexity but are often offset by improved accuracy and efficiency savings.

2. Can pick to light systems handle multiple orders simultaneously?

Yes, many systems support batch or wave picking to increase throughput.

3. How does pick to light compare with voice picking?

Pick to light offers visual guidance, ideal for noisy environments, while voice picking uses audio instructions; both can complement each other.

4. Does pick to light work in cold storage or harsh environments?

Yes, specialized ruggedized pick to light devices are available for challenging conditions.

5. Can the pick to light system integrate with my existing Warehouse Management System?

Most modern pick to light systems offer seamless integration with popular WMS platforms.