Pick to Light order picking technology is used to increase picking efficiency and accuracy in forward pick areas, such as carton flow rack in a pick module. This strategy uses a visual display to lead the order picker through the process of picking each line in the assigned pick zone.
In a split case environment, order pickers pick individual units from full cases into a carton or tote. This process is known as "each picking". The tote enters the pick zone usually by conveyor and the barcode is automatically scanned. After it is scanned, the Warehouse Control System (WCS) recognizes the tote and matches the zone the tote just entered with the required items in the zone that need to be picked for fulfillment of the order. The WCS sends this information to the pick to light zone controller and each pick face associated with a line item to be picked is lit up along with an indicator of the quantity of units to be picked from that specific pick face. When the picker completes the picking from each pick face, he or she confirms the task is complete by pressing a confirmation button next to the light. Once all lines are picked for the order in the zone, the tote is released to the next pick zone.
Some of the advantages of pick to light technology include:
- Increased picking efficiency over paper picking
- Increased picking accuracy over paper picking
- Real time operator productivity tracking
- Dynamic work balancing by using flexible zones
- Hands free operations
- Short learning curve
Watch a video of one of TriFactor's pick to light projects in operation
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