Pick-by-light system

Pick by Light is a light-based picking method in which electronic LED modules at the storage location indicate the quantity to be picked. Employees are guided visually through the picking process and confirm the picks at the touch of a button. The system reports the stock change to the warehouse management system or ERP in real time, significantly reducing search times and error rates.

The software of the pick-by-light system activates the LED displays at the relevant storage locations as soon as an order is ready in the warehouse management system or the picker scans the order with a scanner. The light signals the picking location, and a display shows the picking quantity. The employee confirms the pick, which is then reported back to the WMS or ERP in real time. Depending on the system architecture, additional logic such as prioritization, zone control, or plausibility checks can be integrated to further increase process reliability and efficiency.

A pick-by-light system typically consists of pick modules (LED display, display, acknowledgment button), a control unit, and the technical infrastructure such as a bus system or cabling. In addition, there is software for order control and data processing. The interface to the warehouse management system is also crucial, as this is where orders are generated, inventories are updated, and process data is processed. In larger installations, several zones or work areas are often networked with each other.

The software manages orders, priorities, and feedback within the picking process. It connects the physical system to the WMS or ERP and ensures that orders are processed in the correct order and with the correct quantities. In addition, it enables variants such as batch picking, multi-order picking, or quality checks. In practice, the software architecture has a decisive influence on the scalability, performance, and integration capability of the overall system. LUCA offers flexible and very powerful software for controlling the systems.

Pick by Light is particularly suitable for warehouses with high picking frequencies and fixed storage locations. Typical areas of application include serial picking, e-commerce with clearly structured product ranges, and production supply with recurring material withdrawals. The system shows its strengths when short distances, fast withdrawals, and visual process guidance are paramount. Pick by Light can also ensure high process stability and transparency in multi-stage picking processes or zone-based concepts.

Pick by Light is less suitable for highly dynamic warehouse structures with frequently changing storage locations or a highly fluctuating range of items. In environments with low picking frequencies or very large distances between storage locations, other technologies may be more economical. Even in highly individualized processes without clear repetition structures, it is worth considering whether an alternative picking strategy would be more appropriate. A systematic analysis of order structure, item movement, and throughput is therefore recommended before any decision is made.

The key difference lies in the type of user guidance. Pick by Light works visually via light signals directly at the storage location, while Pick by Voice guides Pick by Voice through the process acoustically via a headset. Pick by Light offers advantages for clearly structured, stationary storage locations and high cycle times. Pick by Voice , on the other hand, Pick by Voice be used more flexibly, for example for longer distances or variable storage structures. The choice depends largely on the process layout, ergonomic requirements, and throughput. We would be happy to advise you on this.

The payback period depends on the order structure, error rate, and personnel costs. In environments with high picking performance and recurring processes, a system can pay for itself relatively quickly by reducing search times and error costs. In addition to increased productivity, quality improvements and shorter training times also play a role. A reliable ROI should therefore take into account both throughput figures and indirect cost factors.

However, usually within 1-2 years.

The investment amount varies depending on the number of storage locations, system architecture, and integration costs. In addition to hardware, software integration and project costs are particularly relevant cost factors. In smaller installations, the focus is often on individual zones, while larger projects may encompass multiple work areas. A reliable calculation therefore takes into account not only the number of picking modules, but also IT interfaces, testing, training, and long-term maintenance.

As a rule, depending on the hardware used, the total hardware costs amount to between €65 and €100 per storage compartment.

Integration is usually carried out via standardized interfaces or project-specific solutions. Order data, article master data, and inventory information are exchanged between the WMS/ERP and the pick-by-light system. It is crucial to clearly define the data structures and process logic, for example for priorities, zone control, or feedback. In more complex environments, an integration layer is often used to connect multiple systems and ensure a stable, scalable architecture.

The LUCA software on a customer-provided Windows server (VM) guarantees fast, powerful, and professional integration.

Yes, for all our implementations, we always draw up a specification sheet with clearly defined process and system requirements. This specifies target processes, interfaces, key performance indicators, and responsibilities. This structured approach reduces project risks and creates transparency for all involved. A detailed analysis phase is particularly important in brownfield projects with existing IT and warehouse structures in order to avoid subsequent adjustments or integration problems.

LUCA has extensive experience in creating specifications and goal-oriented project management.

The project duration depends on the scope, system architecture, and integration complexity. Smaller installations in individual storage areas can be implemented within a few weeks, while larger projects can take several months. Typically, implementation includes the phases of analysis, design, integration, testing, and go-live. A structured project plan with clear milestones ensures that both technical and organizational aspects are taken into account.

For standardized projects, the project duration is 10-12 weeks from the clarification of all details and written order.

Common mistakes arise from insufficient process analysis or an excessive focus on hardware components. Without a clear definition of process logic, data structures, and responsibilities, integration problems or inefficient processes can occur. A lack of training and unclear role allocation also have a negative impact on acceptance in the warehouse. Holistic planning that takes into account both IT architecture and operational processes is therefore crucial for stable operation.

LUCA often performs several simulations of the processes before the hardware is actually put into operation.

Yes, modern systems are generally modular in design and can be expanded zone by zone. Additional storage areas, work areas, or picking zones can be integrated step by step. However, this requires a scalable system architecture—especially in terms of control and software. In larger projects, it is not so much the number of modules as the integration logic that determines how flexibly the system can respond to growing order volumes or new processes.

The hardware and LUCA software are highly scalable and very powerful.

In many cases, pick by light can be combined with other technologies, such as Pick by Voice, mobile data capture systems, automated conveyor technology, and all LUCA systems. In hybrid concepts, each technology handles the processes for which it is best suited. However, such a combination requires an overarching process and IT architecture to ensure that data flows, priorities, and feedback remain consistent. The goal is an integrated overall system rather than isolated individual solutions.

LUCA software with the integrated LUCA communication server (LUCA Core) provides the ideal platform for creating hybrid solutions with multiple technologies. All LUCA systems can be used together.

Pick by Light is considered a proven technology in manual picking. However, its future viability depends largely on the software architecture and integration capabilities. Systems that are open to interfaces, extensions, and data analysis can be adapted more flexibly to new requirements in the long term. Therefore, it is not so much the individual hardware components that are decisive, but rather the ability to further develop processes and IT structures.

Modern pick-by-light systems provide valuable process data, such as pick times, error rates, or throughput per zone. This data enables continuous optimization of layout, routing, and order logic. In conjunction with WMS or BI systems, bottlenecks can be identified and performance indicators evaluated transparently. As a result, the system is not only used operationally, but also strategically to improve overall warehouse performance.

At LUCA, pick-by-light and Pick to Light are not considered in isolation, but as part of an integrated system architecture. In addition to selecting suitable hardware solutions, the focus is on software integration, process analysis, and long-term scalability. The goal is to create a solution that fits seamlessly into existing IT structures and can be expanded with additional technologies as needed. This results in a sustainable overall concept instead of a purely hardware-driven individual installation.

1. At LUCA, Pick by Light stands for high-quality hardware that has been in use for many years -> Blue-Line
2. LUCA Pick to Light as modern and extensively tested hardware with several display series -> Black-Line, White-Line, Mini-Line.
LED-Line is one of the most innovative Pick to Light systems and refers to a special solution with flexible storage compartment widths.