Pick by Light Systeme

Pick by Light is a light-guided picking method in which electronic LED modules at the storage location display the quantity to be picked. Employees are visually guided through the picking process and confirm each pick with the push of a button. The system reports inventory changes in real time to the warehouse management system or ERP, thereby 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 indicates the picking location, and a display shows the quantity to be picked. The employee confirms the pick, which reports the transaction 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 picking modules (LED indicators, displays, confirmation buttons), 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, inventory is updated, and process data is processed. In larger installations, multiple zones or work areas are often networked together.

The software manages orders, priorities, and confirmations 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. Additionally, it supports variants such as batch picking, multi-order picking, or quality checks. In practice, the software architecture plays a decisive role in determining the scalability, performance, and integration capabilities of the entire system. LUCA offers flexible and highly powerful software for controlling these systems.

Pick by Light is particularly well-suited for warehouses with high picking frequencies and fixed storage locations. Typical applications include batch picking, e-commerce with clearly structured product ranges, or production supply with recurring material withdrawals. The system truly shines when short distances, fast retrievals, and visual process guidance are key priorities. Even in multi-stage picking processes or zone-based concepts, Pick by Light can ensure high process stability and transparency.

Pick-by-Light is less suitable for highly dynamic warehouse structures with frequently changing storage locations or a product range that fluctuates significantly. In environments with low picking frequencies or very long distances between storage locations, other technologies may be more cost-effective. Even for highly customized processes without clear repeat patterns, it is advisable to assess whether an alternative picking strategy would be more appropriate. A systematic analysis of order structure, item movement, and throughput is therefore recommended before making any decision.

The key difference lies in the type of user guidance. Pick by Light uses visual light signals directly at the storage location, while Pick by Voice guides Pick by Voice through the process using audio cues via a headset. Pick by Light offers advantages in clearly structured, fixed storage locations with high throughput. Pick by Voice , on the other hand, Pick by Voice be used more flexibly, for example over longer distances or in variable warehouse layouts. The choice depends largely on process layout, ergonomic requirements, and throughput. We would be happy to advise you on this.

The payback period depends on order structure, error rate, and labor costs. In environments with high picking performance and repetitive 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 robust ROI should therefore take into account both throughput metrics and indirect cost factors.

Usually, however, within 1–2 years.

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

Generally, depending on the hardware used, the total hardware costs range from €65 to €100 per storage bay.

Integration typically takes place via standardized interfaces or project-specific solutions. This involves the exchange of order data, product master data, and inventory information between the WMS/ERP and the pick-by-light system. A clear definition of data structures and process logic—such as for priorities, zone control, or status updates—is crucial. In more complex environments, an integration layer is often used to connect multiple systems and ensure a stable, scalable architecture.

The LUCA software running on a customer-provided Windows server (VM) ensures fast, high-performance, and professional integration.

Yes, for all our implementations, we always create a requirements specification with clearly defined process and system requirements. This document outlines target processes, interfaces, key performance indicators, and responsibilities. This structured approach reduces project risks and ensures transparency for all stakeholders. A detailed analysis phase is particularly crucial for brownfield projects with existing IT and warehouse infrastructure to avoid subsequent adjustments or integration issues.

LUCA has extensive experience in developing requirements specifications and providing goal-oriented project management.

The project duration depends on the scope, system architecture, and complexity of integration. Smaller installations in individual storage zones can be implemented within a few weeks, while larger projects may take several months. Typically, the implementation includes the following phases : 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 time all details have been clarified and a written order has been placed.

Common mistakes often stem from inadequate process analysis or an excessive focus on hardware components. Without a clear definition of process logic, data structures, and responsibilities, integration issues or inefficient workflows can arise. A lack of training and unclear role assignments also have a negative impact on acceptance within the warehouse. Comprehensive planning that takes into account both IT architecture and operational workflows is therefore crucial for stable operations.

LUCA often runs 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 in stages. Additional storage locations, work areas, or picking zones can be integrated incrementally. However, this requires a scalable system architecture—particularly in terms of control systems 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 the 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 collection systems, automated conveyor systems, 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, featuring the integrated LUCA Communication Server (LUCA-Core), provides the ideal platform for creating hybrid solutions that combine multiple technologies. All LUCA systems can be used together.

Pick-by-Light is considered a proven technology in manual order picking. However, its future viability depends largely on the software architecture and its ability to integrate with other systems. Systems that are open to interfaces, extensions, and data analysis can be adapted more flexibly to new requirements over the long term. Therefore, what matters most is not the individual hardware components, but the ability to further develop processes and IT structures.

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

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

1. At LUCA, "Pick by Light" refers to high-quality hardware that has been in use for many years -> Blue-Line
2. LUCA Pick to Light the term " Pick to Light " Pick to Light 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 specialized solution with flexible bin widths.