Assembly with pick-by-light
Pick-by-Light optimally supports assembly at an assembly table, minimizes errors, and increases the quality and performance of employees. Freely configurable with many additional options. Connection to SAP or other systems possible.
Pick-by-Light
Assembly
Howdoes pick-by-light support assembly?
- The assembly instructions are scanned into a scanner.
- The pick-by-light displays light up for the first assembly step and show the quantities directly on the containers.
- The technician removes the parts and confirms the assembly on the button.
- Once all steps have been confirmed, the installation is complete.
Which pick-by-light displays are used for assembly?
specialized displays
If the number of components in the assembly instructions is always = 1, the LED display with button is used:
If, according to the installation instructions, several components must be removed from a compartment, the standard display with a 3-digit numeric display is used:
The compartment displays are mounted directly above or below the containers. Withdrawals from the individual compartments are confirmed directly on the displays. Each assembly step is confirmed on a central button or the info display.
information displays
Detailed information about the assembly process is displayed to the employee on a central information display:
If screens are used at the table, the info display is not necessary.
You can find a complete list of possible displays in the article:
Option: Screens at the assembly station
If the assembly is very complex and the employee needs to see additional assembly instructions, construction manuals, CAD drawings, or images, screens are installed at their assembly station.
The position of the screens is always very individual and depends on the ergonomics of the assembly workstation. Various tools, testing equipment, and measuring devices can also be positioned on the table. The assembly table can be used as a test bench or test station.
Option: Sensors monitor assembly
Optionally, each display can be equipped with a sensor for automatic access monitoring.
Only when the employee has reached into the compartment is it possible to confirm with the button.
The sensor improves the quality of the sampling process.
If the quantity is 1, confirmation is automatic. For other quantities, the withdrawal is confirmed individually or centrally, but only if the active sensors have correctly registered the accesses.
If the employee reaches into the wrong compartment, an error message and an audible signal are emitted.
Configuration of assembly stations
If there is no connection to a production system, the individual assembly steps must be configured manually.
- To start the configuration, a special "setup" barcode is scanned.
- The unique barcode is then scanned to identify the assembly list.
- The info display shows the text "Step 1." The +/- buttons help you select the steps. For each step, the configured pick-by-light displays on the compartments light up.
- The acknowledgment button on the compartment display switches the individual displays on and off.
- The quantity can be set directly on the compartment using the +/- buttons.
- Once everything is configured, scan the "Save" barcode and the configuration will be saved.
Configuration is very simple and requires no IT knowledge. The two special barcodes ("Setup" and "Save") are available to the assembly manager.
Connection to a production system
A system connection to SAP or another production system is possible without any problems, but requires some coordination and possible customer-specific software adjustments.
Flexibility through dynamic containers
In some situations, a large number of different parts must be provided on the table, depending on the assembly requirements and assembly steps. However, space on an assembly table is very limited. The innovative Pick-by-Frame can be used as a solution for this.
First, the required containers are picked from a picking warehouse using a picking trolley.
For this purpose, a mobile structure (Pick-by-Frame®) with mobile Pick-by-Light displays is docked to the trolley. The system guides the picker to the storage locations in the warehouse and assists them in distributing the components into the containers. The trolley is clearly marked and managed by the production system.
Once the picking trolley is ready, it is placed on a frame at the assembly station in accordance with the assembly list. The trolley is registered at the table using its barcode or RFID. Assembly only begins once the dynamic containers are correctly positioned.
FAQ
Which assembly tables can be equipped with pick-by-light?
Any assembly with containers or cartons can be retrofitted. The displays can be attached at any mounting location. If the compartments are very small, the small displays from the PTF-S series can be used.
How many pick-by-light displays can be operated at one assembly table?
The maximum number is not defined. A standard controller controls up to 150 displays. Several controllers can also be used at one assembly station. However, the workstation should be clearly laid out and ergonomically designed. Therefore, there should not be too many displays.
Does the assembly table need to be connected to SAP or other systems?
No. The assembly table can also operate without any connection to a higher-level system. The assembly steps are then configured manually and do not require any special IT knowledge.
