“Pick-by-Light” (also “Pick-to-Light”) is a visually guided order-picking method used in warehouses and production. Light modules (LED + display) at each bin/location indicate where to pick and how many units. Operators confirm the pick directly at the module (e.g., via button), reducing travel and search time as well as errors while increasing throughput. Pick-by-Light is typically integrated with a WMS/ERP and is often combined with “Put-to-Light” for sorting/consolidation.
Order & wave management: Batch/wave creation, zone assignment, labor allocation.
Real-time light module control: Display of slot, quantity, remainder; confirmation and auto-advance to next pick.
Path & zone optimization: Sequencing to minimize travel; multi-order and zone picking.
Error prevention & handling: Validations, barcode/RFID double-check, mispick alerts, lockout logic.
Put-to-Light support: Reverse process for sorting/consolidation to target totes or routes.
Replenishment & inventory: Replenishment triggers, min/max monitoring, cycle counting/zero count.
Resource management: Slot/bin management, occupancy, priorities (rush orders, cut-off times).
Performance analytics: KPIs (picks/hour, first-pick accuracy, error rate), live dashboards, heatmaps, OEE-like metrics.
Quality & compliance: Batch/expiry/serial capture, GMP/pharma options, full traceability.
User guidance & ergonomics: Hands-free flows, multilingual displays, visual/acoustic cues.
Integration & APIs: WMS/ERP/MES connectivity, scanners/Wearables/AMRs, REST/message bus, edge controllers.
Maintenance & diagnostics: Module inventory, self-tests, firmware updates, fault monitoring.
An e-commerce fulfillment center groups orders into waves and cuts pick time per line by 30% through visual guidance.
A pharma distributor uses serial capture at the module to prevent mispicks and meet GxP requirements.
An automotive supplier performs zone-based kitting for assembly lines; auto-advance guides operators step by step.
A grocery dark store combines batch picking with put-to-light for rapid order consolidation by delivery route.
A 3PL scales temporary light strips and staff in high-traffic zones during seasonal peaks.
A cold-storage facility relies on button confirmations with gloves and acoustic cues to reduce errors at −20 °C.
A returns process uses put-to-light to re-slot items efficiently and update inventory in real time.