Put to Light: Distributing and Sorting Goods
In this comprehensive guide to Put-to-Light, we’ll help you find the best solution for modern, paperless sorting and goods distribution. Here, we’ve compiled the key features of a two-stage picking system using Put-to-Light, as well as the advantages and disadvantages of the process. With this detailed information, we aim to make your decision to purchase a Put-to-Light system as easy as possible. Enjoy reading!
What is Put to Light?
Put to Light with bin indicators is a highly modern, light-guided, paperless method for sorting, distributing, and picking goods. The storage location of the inventory items is displayed directly to the picker via a bin indicator at the destination bin and confirmed using the confirmation button or sensor.
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Put to Light System: Key Points at a Glance
- Put to Light is the reverse process of Pick-by-Light.
- During the sorting process, the signal light indicates the exact placement location of the item to the picker.
- The sorting process is greatly accelerated by the light signals.
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| Type | PTF-L-6 |
| Height | 50 mm |
| width | 70 mm |
| Depth | 25 mm |
| System | Ideal for sorting and product distribution. Controlled via a Windows server using LUCA software. Linux available upon request |
| Display | none |
| LED | two 7-color high-intensity signal lights, divided horizontally |
| Buttons | Durable confirmation button, function key |
| Sensor | Optional: as automatic pick detection. Learn more here: Pick-by-Light sensor |
| Applications | Bin label for paperless sorting, goods distribution sequencing, and two-stage picking |
| Performance | up to 400 items per hour |
| Quality | 100% sorting using sensors |
| Costs | €90 as the budget for hardware per storage compartment, including accessories |
| Learn more about PTF-L-6 |
How does Put-to-Light work in two-stage picking?
Before the process begins, a batch of orders is compiled in the warehouse management system (Multi-Order-Picking). In a two-stage picking process, the goods are first picked from the warehouse and placed into several containers. The containers are then transported to the sorting station and distributed across multiple orders using the put-to-light system. Depending on the solution, there are two different sorting procedures:
1. Sorting by identical items
If the picking system sorts items by type into bins, each bin will always contain the same items. To distribute the goods, all that is needed is to scan the bin barcode. The system then activates all the compartment indicators on the sorting rack with the corresponding quantities.
The picker confirms the placement of the items by pressing the confirmation button. This method is used only when there are a small number of products.
2. Collection boxes
In the first stage of order picking, different items are first placed into the collection bin. When distributing the goods, the employee must scan each item again and sort it separately. The confirmation process at the confirmation button is the same. This procedure is slower than the first one, but offers greater flexibility when dealing with a wide range of items.
Entering the quantity into the put-to-light process
With some solutions, the items in the box can be grouped very easily (e.g., CDs, DVDs, etc.), which means they must be removed in groups rather than individually.
In this case, the quantity of items can be entered on a screen at the sorting station. During the sorting process, the barcode then only needs to be scanned once. This saves a significant amount of time and money during sorting.
Sensors during acknowledgment
To improve sorting performance and quality, sensors can also be installed on the bin displays as an option. These sensors automatically confirm when items are placed in the sorting bins, thereby sending a confirmation signal to the inventory management system without the need to press the confirmation button. Using sensors increases performance by approximately 15%.
What is important in a put-to-light system?
The most important factor in a Put-to-Light system is the response time after the barcode is scanned. The picker should not have to wait for the bin light to turn on. In our experience, the system’s response time should not exceed 250 ms. Our communication server (LUCA-Server) guarantees these response times without any issues.
Advantages
Among the biggest advantages of put-to-light picking are:
- Employees can quickly find their way around thanks to the illuminated compartment indicators (minimal search time)
- Direct display of the quantity in the storage bin (destination bin)
- Immediate confirmation of placement at the confirmation button or sensor and immediate response to the warehouse management system
- Fewer errors, better performance
Disadvantages
However, the process also has some drawbacks:
- Limited flexibility due to the fixed batch size (number of storage locations)
- relatively high investment costs (as with Pick to Light)
Conclusion
Put-to-Light solutions are methods used in two-stage paperless order picking, in which sorting in the second stage is performed using illuminated bin indicators. In this sense, it is a reverse Pick-by-Light process, in which items are not picked but rather placed (put) according to the light signals. Read more about Put-to-Light on Wikipedia or contact us to learn more. We’d be happy to advise you.