's Maintenance & Service for a Pick-by-Light System

Why maintenance?

Our pick-by-light components are essentially maintenance-free. The controllers feature passive cooling, eliminating the need to replace filter mats or active fans. The bin indicators are extremely robust and professionally constructed from heavy-duty aluminum.

The mechanical confirmation button is rated for several million keystrokes, is virtually indestructible, and does not need to be replaced. No membrane keys are used. The flat keys of the PTF-S series are capacitive and can even be operated while wearing work gloves.

In practice, however, it turns out that some employees are very careless with the system. The display panels are often subjected to significant mechanical stress. In some cases, the wiring is also damaged.

Our pick-by-light systems often play a decisive role in determining the quality and performance of order pickers during order picking, at assembly stations, and in production. For this reason, we recommend that regular maintenance of the systems be performed on-site. This maintenance must be carried out by trained personnel.

This includes maintenance

To ensure smooth operation, the following maintenance tasks are performed on the Pick-by-Light system:

1. Verification of the data availability of all Pick-by-Light components (via our software).
2. Inspection of the wiring and terminal blocks.
3. Investigation of mechanical damage to the panel displays.
4. Performing the zone test and checking the buttons and LEDs.
5. Visual inspection of the pick-by-light controllers.
6. Testing and inspection of peripheral devices such as scanners, RFID readers, scales, etc.
7. Review of documentation and spare parts.

On-site maintenance can be performed by us or by the customer’s trained personnel.

Expert Tip:
For control panels mounted horizontally (e.g., on the side of conveyor systems) that are heavily soiled by cardboard, the displays should be vacuumed regularly. This prevents large dust particles from accumulating on the confirmation button. If the contamination is very heavy, we offer compartment displays with touch confirmation (without a mechanical button) as an alternative to the standard version.

Software Services

A pick-by-light system consists not only of hardware but also of software. It is not only the connections to the higher-level system that are crucial for the stable operation of the equipment. Software maintenance is also one of the key measures for ensuring continuous operation. Software maintenance is carried out very easily via remote maintenance (VPN) and is performed by us.

What the software service includes

The LUCA software is installed on a client-provided server system (Windows or Linux). A stable and fast internet connection to the LUCA-Server is LUCA-Server for the software to function properly.

The following service work will be performed:

1. Analysis of the internal LUCA log file system and the automatic reorganization of files.
2. Monitoring system performance and system resource utilization (memory, CPU, disk space).
3. Review of the database and its load (possible reorganization of the data).
4. Verification of backup mechanisms and potential switchover to the backup server (hot swap).
5. Testing the automatic startup mechanisms during a reboot.
6. Review of the operating system's and antivirus software's update mechanisms.

Regular software maintenance helps ensure high system quality and stability. In particular, automatic updates for the operating system and antivirus software are sensitive components that require careful coordination between our team and the customer’s IT department.

Maintenance & Service Contracts

For complex facilities and critical production-related systems, we offer our customers maintenance and service contracts. We have various models that are tailored to each customer’s specific needs. In most cases, maintenance is performed once a year.