28 November 2021 The evolution of the supply chain does not stop. More and more new solutions and tools are emerging that aim to increase efficiency, productivity, and accuracy in processes so that companies can offer the best shopping experience to their customers and reduce their costs. One of these is pick-to-light (PTL or pick-by-light), designed to optimize order picking and eliminate errors. What is Pick to Light? Pick-to-light is a simple yet robust system where each storage compartment has a light indicator and a display, along with a confirmation button. Throughout the entire picking process, the operator is guided by the lights, thus eliminating the need for paper pick lists. For pick-to-light to be picked, it must be integrated into the WMS system. It is this software that lights up the display and indicates the number of items to be ordered based on each order. It is worth noting that it is essential to evaluate the carton, that is, the calculation of the order’s cubic volume and its correct division into multiple volumes: a decisive role of the WMS for those who want to use PTL. How does pick-to-light work in practice? During sorting, the operator moves along the shelves (usually of the flow rack type) and the products to be sorted into the bin are indicated by the light that turns on exactly where they are located. The display also indicates the quantity of each item to be picked. Thus, when the light turns on, the operator picks the goods and presses the confirmation button, indicating that the product has already been picked and placed in the sorting bin. For example: an order requests 2 bottles of shampoo and 3 soaps. During order processing, the WMS system sends a command to pick-to-light. The operator, who is in front of the flow rack, emits a beep of the code from the sorting box. Then, the light in the compartment where the shampoos are located turns on and the display indicates 2. They pick the two items and press the confirmation button. Then, the soap position light turns on and the display shows the number 3. The employee picks three units of the item and clicks the confirmation button. Done! The order has been separated and can now be sent for shipping! In the solution offered by our partner, there is the possibility for the operator to scan the product’s barcode to confirm the separation. This functionality will be very useful for reading the datamatrix barcode with the serial number, as required by the Drug Traceability Law. Furthermore, with the integration with the WMS, as soon as the items are sorted and confirmed, the software automatically updates the warehouse inventory, ensuring greater control and accuracy. Installation The installation of pick-to-light hardware is very simple and offers many advantages. Basically, it consists of the following structures: • Control computer with interface to the upper system • Line controller (* the quantity depends on the size of the installation) • A picking surface (display with light indicator) for each storage position Almost all PTL systems are equipped with additional keys (Plus, Minus, and F key for special functions) that help correct errors. Operations where pick-to-light is indicated Pick-to-light is often applied to area picking (picking zone), where each picker works in a designated area to reduce offsets. After a part of the order is completed in one zone, the pick box moves to the next zone, where more items are picked, and so on, until the order is completed. This assembly line-style approach based on teamwork keeps all tabs on the picking line. Due to these particularities, pick-to-light ends up being indicated for operations that separate fractions, as in the case of e-commerce. It can also be interesting for industries in the process of separating raw materials. In general, PTL works best when applied to operations where a relatively small number of SKUs (about 20%) represents a high percentage of daily order volume (about 80%). Among the sectors/segments where pick-to-light works well are: • Retail • Direct Store Delivery • E-commerce and catalog • Pharmaceuticals • Medical products • Automotive • Health and beauty, cosmetics • Beverage distribution • Grocery and convenience stores • Electronics • Manufacturing To assess whether PTL will be feasible in your operation, enlist the support of your WMS provider. Benefits With the pick-to-light system, there is a drastic reduction in errors, as well as increased speed in picking. The company also becomes more sustainable by giving up the use of paper lists. In addition to these advantages, we can mention others such as: Ease of use: training operators in traditional picking can take hours, depending on the size and complexity of the warehouse. With an efficient pick-to-light system, you can reduce training to 30-45 minutes. Integration: pick-to-light can be integrated with your WMS and ERP system, as well as other automated systems, such as RF and voice picking, which bring greater control and efficiency to your operations. Perfect order: from the customer’s service perspective, the greatest advantage of pick-to-light is the accuracy and agility in order fulfillment. Cost reduction: traditional picking methods represent one of the largest expenses in intralogistics operations (up to 60% of total cost). However, when implementing systems that speed up picking and provide greater order accuracy, cost savings are certain. Remember: the smaller the errors, the fewer losses, rework, and returns. Real Gains It is estimated that pick-to-light can generate productivity increases from 30 to 50% in picking and bring 99.9% more accuracy in order fulfillment. How does Pick to Light work? Deagor WMS per ecommerce può aiutarti!