Pick to Light
Pick to Light visual guidance in order picking, whereby LED displays at the storage location indicate the correct picking location and quantity. Modern pick-to-light systems guide employees safely through the picking process and report confirmation to WMS or ERP systems in real time.
- Visual guidance with pick-to-light displays directly at the storage location
- Display of removal location and pick quantity via LED
- Real-time feedback to WMS and ERP systems
- Scalable pick-to-light architecture for warehouses, production, and assembly
Pick to Light basiert auf dem bewährten Prinzip der klassischen lichtgestützten Kommissionierung, das bei LUCA durch moderne, modulare Display-Varianten in unterschiedlichen Serien weiterentwickelt wurde.
What is Pick to Light?
Pick to Light is a light-based picking method in which LED displays or indicators directly at the storage compartment show the picking location and the quantity to be picked. Employees are guided visually and confirm the pick using a button or sensor.
Pick to Light technically implemented in a pick-to-light system consisting of displays, controllers, and software. The systems guide employees visually through the picking process, report confirmations back to WMS or ERP systems in real time, and are used in warehouse logistics, production supply, and e-commerce warehouses.
How does Pick to Light work?
Pick to Light the picking process by providing direct visual guidance at the storage location. It is controlled centrally via the warehouse management system or the ERP system. Pick orders are transmitted in real time to the Pick to Light system, which guides employees step by step through the picking process. This eliminates search times, media breaks, and manual checks.
The functionality of Pick to Light deliberately kept simple to ensure high process reliability and short training times.
Pick process flow with Pick to Light
The picking process begins with the transmission of a picking order from the warehouse management system. Scanners, RFID readers, or conveyor technology signals can also be used for the requests. As soon as the order is started, the system activates the corresponding pick-to-light displays. A light signal (large LED) shows the employee the correct storage location, while the display shows the quantity to be picked.
The picker removes the displayed quantity and confirms the pick directly on the acknowledgment button on the display. In the follow-me method, the next pick location is only activated automatically. This sequential process ensures clear, intuitive user guidance and minimizes picking errors, as the focus is always on the currently relevant storage location. It also allows several employees to work simultaneously (multi-user picking) (multiple LED colors).
Acknowledgment, feedback, and process reliability
Nach der Entnahme bestätigt der Mitarbeitende den Pick über einen Taster oder eine Touchfunktion am Display. Die Quittierung wird in Echtzeit an das WMS- oder ERP-System zurückgemeldet. Dadurch bleibt der Lagerbestand stets aktuell und der Fortschritt des Auftrags ist jederzeit transparent nachvollziehbar.
Additional security mechanisms such as multiple confirmations, plausibility checks, or visual feedback further increase process reliability. Errors are detected early on and can be corrected immediately before they affect downstream processes.
Why are pick-to-light systems used?
Pick-to-light systems are used to make picking processes faster, safer, and more economical. Visual signals directly at the storage location guide employees to the correct picking location and allow them to confirm picks immediately.
The key benefits of a pick-to-light system are:
- Reduced search times thanks to visual guidance
- Higher picking performance with consistent process quality
- Short training periods thanks to intuitive operation
- Modular expandability with increasing storage density or picking frequency
Pick to Light particularly Pick to Light for companies that want to implement low-error and scalable picking in warehouse logistics, production supply, or e-commerce.
Advantages of Pick to Light visual picking
Pick to Light numerous advantages for companies that want to make their picking processes more efficient, safer, and more economical. Direct visual user guidance at the storage location minimizes manual errors and standardizes processes. At the same time, the use of economically optimized display hardware enables cost-conscious implementation of visual picking.
- High picking speed thanks to visual guidance.
- Reduction of errors and rework.
- Quick training of new employees.
- High process reliability with consistent quality.
- Scalability for different warehouse sizes.
Reduced error rate thanks to visual user guidance
One of the biggest advantages of Pick to Light the significant reduction in picking errors. Light signals and displays clearly guide employees to the correct storage location and indicate the correct quantity to be picked. This largely eliminates misinterpretations that can occur with paper-based lists or manual scans.
The clear visual guidance ensures consistently high picking quality, especially with high picking frequencies or changing personnel. Errors are detected early and can be corrected directly at the point of origin.
Increase in picking performance
Pick to Light the picking process by eliminating search times and keeping the focus on the currently relevant pick location. Employees follow clear, sequential user guidance that reduces unnecessary movements and interruptions.
Automating feedback to the higher-level system optimizes the entire process flow. In practice, this results in significantly higher picking performance—especially for recurring orders and standardized processes.
Ergonomics, simple operation, and short training periods
Pick-to-light systems are intuitive to use and do not require extensive training. New employees can become productive within a short period of time, as the visual guidance is language-independent and does not require complex inputs.
Pick to Light also offers Pick to Light from an ergonomic perspective. Eliminating hand scanners and paper reduces physical strain and makes daily work easier. This contributes to greater acceptance among employees and stable process quality.
Areas of application for Pick to Light warehouse type
Pick to Light for a wide range of warehousing and picking processes that require fast, error-free, and cost-effective order processing. The system really comes into its own in areas with recurring picks, clearly defined storage locations, and high pick frequencies. Thanks to its modular display hardware, Pick to Light can be Pick to Light adapted to different types of warehouses and process requirements.
Pick to Light shelf and small parts warehouses
In shelf and small parts warehouses, Pick to Light significantly Pick to Light search times. The visual display directly on the storage compartment reliably guides the picker to the correct picking location and clearly indicates the required quantity. This allows consistent picking performance to be achieved even with a wide variety of items.
Pick to Light offers Pick to Light clear advantage over paper- or scanner-based processes, especially for manual picking with a high repetition rate. New employees can be trained quickly, as the user guidance is intuitive and language-independent.
Pick to Light production supply
Process reliability plays a key role in production logistics. Pick to Light the error-free provision of materials, assemblies, or components directly on the production line. Visual guidance prevents picking errors that could lead to production interruptions or rework.
Pick to Light stabilize material flows and reliably ensure production supply, especially in just-in-time or just-in-sequence processes. Direct feedback to the higher-level system ensures transparent inventory management.
Pick to Light e-commerce, shipping, and spare parts warehouses
In e-commerce and shipping, short throughput times and high flexibility are crucial. Pick to Light fast order picking even when order volumes fluctuate greatly. Seasonal peaks can be easily absorbed by using additional displays or temporary storage zones.
Pick to Light also supports error-free Pick to Light in spare parts warehouses with a wide variety of products. Clear visual guidance reduces picking errors and ensures high delivery quality, which is particularly important in the service and after-sales sector.
Areas of application for Pick to Light industry
Pick-to-light systems are used wherever picking processes need to be clearly structured, repeatable, and implemented with a high picking frequency.
Warehouse logistics and intralogistics
In warehouse logistics, pick-to-light supports fast and error-free picking of items from shelves, containers, or flow channels. Displaying the quantities to be removed directly at the storage location reduces search times and facilitates standardized processes in manual storage areas.
Production and material provision
In production environments, the system is often used for material provision. Parts and components can be provided in a structured and traceable manner, ensuring that assembly and manufacturing processes run continuously and without interruptions.
Spare parts and components warehouse
Pick-to-Light is particularly suitable for spare parts and component warehouses with many items and clearly defined withdrawal quantities. The visual guidance ensures clarity and supports reliable picking, even with frequently changing orders.
E-commerce and fulfillment
In e-commerce and fulfillment, this solution enables efficient processing of customer orders. Standardized picking processes can be scaled and support short throughput times while maintaining consistent process quality.
Assembly and work stations
Pick-to-light is used at assembly and workstations to guide employees step by step through defined picking or staging processes. This supports consistent workflows and facilitates the training of new employees.
System structure of the pick-to-light system
A pick-to-light system consists of several coordinated components that together enable an efficient and error-free picking process. The system structure is modular and can be flexibly adapted to different warehouse environments and requirements. The key components and their functions within the overall solution are explained below.
- Pick-to-Light-Displays: Anzeigen am Lagerplatz zur Darstellung von Mengen, Pickinformationen und Statusmeldungen.
- Pick-to-Light-Controller: Steuern die Kommunikation zwischen Displays und der zentralen Software.
- Mounting and cabling systems: For flexible installation on shelves, flow channels, or workstations.
- Central software: For managing pick orders, process logic, and system integration.
- Interfaces: Connection to warehouse management systems (WMS), ERP or host systems.
Display-Serien des Pick-to-Light-Systems
Pick-to-Light-Displays sind die zentrale Hardware eines Pick-to-Light-Systems und ermöglichen die visuelle Führung der Mitarbeitenden in Kommissionierprozessen.
Black-Line
The Black-Line the latest pick-to-light display series and has been designed to be particularly economical for standardized picking processes in logistics, assembly, and production.
White-Line
The White-Line a versatile pick-to-light display series with numerous display variants and different display formats. It is particularly suitable for applications with varying process requirements that call for flexible displays and individual configurations.
Mini-Line
The Mini-Line a compact pick-to-light display series for space-saving solutions in narrow storage compartments and workstations. It is particularly suitable for standardized picking processes in confined spaces and where clear visual guidance is required in limited space.
Integration of Pick to Light existing IT systems
Pick to Light can be seamlessly integrated Pick to Light existing IT landscapes without requiring any fundamental changes to existing systems. Pick-to-light systems are designed to complement existing warehouse processes rather than replace them. This means that proven processes can be retained while the advantages of visual picking can be exploited in a targeted manner.
Special emphasis is placed on easy connection to warehouse management systems (WMS) and ERP systems to ensure a consistent, media-break-free flow of information.
Connection to WMS and ERP systems
Pick to Light connected directly to the existing WMS or ERP. Order data, storage location information, and feedback are exchanged via standardized interfaces or middleware. This ensures that pick orders are transmitted to the Pick to Light displays in real time.
The system logic remains entirely in the leading system. Pick to Light as the executing system for visual user guidance and does not interfere with existing process control. This simplifies integration and significantly reduces implementation costs.
Integration without changing the system
A key advantage of Pick to Light the ability to implement the system without changing or adapting the existing IT structure. Companies do not need to replace or make any major changes to their WMS or ERP systems. Existing processes are simply supplemented with a visual component.
This approach protects existing investments and enables gradual implementation. Individual storage areas or picking zones can be equipped with pick-to-light displays without affecting overall operations.
Real-time data, transparency, and monitoring
Real-time feedback on all picking processes provides a high level of transparency regarding the current order status and stock levels. Every confirmation on the display is immediately reported back to the leading system and processed there.
This transparency enables effective monitoring of picking processes. Bottlenecks, delays, or sources of error can be identified early on and remedied in a targeted manner. Pick to Light thus Pick to Light not only operational picking, but also the continuous optimization of warehouse processes.
Pick to Light use at international industrial companies
Pick-to-Light systems from LUCA are used in international warehouses, production facilities, and distribution centers. Companies in the automotive, retail, electronics, and consumer goods industries use Pick to Light increase efficiency, process reliability, and transparency.
LUCA implements pick-to-light systems worldwide and supports companies in the economical and scalable optimization of their picking processes. You can find further international pick-to-light references on our reference page.
Arvato Services
BSH
Danfoss
DB Schenker
Deutsche Post
Dirks Group
FCA
Fuchs Gruppe
Geis
Huf
IVECO
MAN
Philips Lightning
Rehau
Schnellecke
Schwarzkopf
SEAT
SKODA
Telekom
VW
Planning and project management for a pick-to-light system
The successful introduction of a pick-to-light system begins with structured planning. The aim is to optimally adapt visual picking to existing warehouse processes while ensuring cost-effective implementation. Both technical and organizational aspects are taken into account to ensure smooth implementation.
Careful project planning ensures that Pick to Light is used Pick to Light where it brings the greatest benefit.
Analysis of warehouse structure and processes
The planning process begins with an analysis of the existing warehouse structure and picking processes. Key factors include the number of storage locations, picking frequency, item structure, and employee walking distances. Seasonal fluctuations and future growth scenarios are also taken into account.
This analysis forms the basis for deciding which storage areas are Pick to Light for Pick to Light and how the displays can be optimally positioned. The aim is to enable efficient user guidance and avoid unnecessary movements.
Selecting the right display series
The appropriate pick-to-light displays are selected based on the process analysis. Factors such as display size, scope of information, mounting type, and operating concept play a key role in this process. Different storage areas may require different display series in order to meet the respective requirements.
Choosing the right display hardware is crucial for the cost-effectiveness and acceptance of the system. Pick to Light it Pick to Light to tailor the equipment level specifically to the intended use.
Gradual introduction and pilot operation
To minimize risks, Pick to Light is Pick to Light introduced in stages. The system can be tested and optimized under real conditions in a pilot area. Experience gained from pilot operation is then incorporated into the rollout to other warehouse areas.
This approach facilitates acceptance among employees and allows for adjustments to be made before the system is fully rolled out. At the same time, ongoing operations remain stable during the introduction phase.
Cost-effectiveness and ROI Pick to Light
| key figure | Manual picking | With pick-to-light |
|---|---|---|
| Picks per hour | approx. 110 | approx. 250–310 |
| error rate | 1–3% | < 0,2 % |
| training period | Several days | A few hours |
| process reliability | Depending on experience | System-guided |
Pick to Light ist darauf ausgelegt, visuelle Kommissionierung wirtschaftlich umzusetzen. Durch den Einsatz kostenoptimierter Displays lassen sich Investitionen gezielt steuern, ohne auf die Vorteile des Prinzips verzichten zu müssen. Die Wirtschaftlichkeit ergibt sich dabei nicht nur aus den Anschaffungskosten, sondern vor allem aus den langfristigen Einsparpotenzialen im laufenden Betrieb.
A correctly planned pick-to-light system pays for itself within a short period of time in many applications.
Investment costs and cost structure
Die Investitionskosten eines Pick-to-Light-Systems hängen maßgeblich von der Anzahl der Lagerplätze, der gewählten Display-Serien und dem gewünschten Ausstattungsniveau ab. Durch die wirtschaftlich optimierte Hardware sind die Einstiegskosten im Vergleich zu klassischen Installationen geringer.
Another advantage is the modular cost structure. Companies can introduce Pick to Light and tailor investments to their actual needs. This keeps the financial burden predictable and scalable.
Potential savings through error reduction and increased efficiency
A significant economic advantage of Pick to Light the significant reduction in picking errors. Fewer picking errors mean lower costs for rework, returns, and complaints. At the same time, delivery quality increases, which has a positive effect on customer satisfaction and service levels.
In addition, visual user guidance leads to higher picking performance. Search times are eliminated, processes are standardized, and employees work more productively. These effects have a direct impact on ongoing personnel costs.
Scalability and investment security
Pick to Light a high level of investment security, as the system can be expanded flexibly. New storage locations, additional picking zones, or modified layouts can be easily integrated without having to replace existing installations.
This scalability ensures that Pick to Light remains economical Pick to Light as requirements grow. Companies are not investing in a rigid solution, but in a system that grows with the warehouse and the processes.
ROI for Pick to Light
A simplified sample calculation helps to assess the cost-effectiveness of a pick-to-light system. The actual values always depend on the individual process, item structure, and order volume (see left).
In many solutions, higher picking performance, reduced error costs, and shorter training times mean that a pick-to-light system pays for itself after only a short time.
The potential savings that can be achieved in your specific process can be determined during an individual consultation.
Pick to Light to other picking systems
In intralogistics, companies have various picking systems at their disposal. The most suitable solution depends on process requirements, warehouse structure, and economic conditions. Pick to Light a visual, hardware-based system that is particularly effective for recurring picks and clearly defined storage locations.
Comparing it with other systems helps to better classify its respective strengths and limitations.
Pick to Light . Pick by Voice
Pick by Voice employees through the picking process using voice-based instructions. This system is particularly suitable for large-volume warehouses with long walking distances and hands-free work. However, Pick by Voice is Pick by Voice dependent on voice quality, ambient noise, and training requirements.
Pick to Light , is completely language-independent. The visual user guidance works reliably even in noisy environments and requires only minimal training. Pick to Light offers greater Pick to Light and clearer user guidance, especially for recurring picks with high cycle times.
Pick to Light . scanner-based picking
Scanner-based picking is widely used and flexible. However, employees must actively scan, read displays, and interpret information. This increases the number of steps and can lead to fatigue or errors when picking frequencies are high.
Pick to Light this complexity, as all relevant information is displayed directly at the storage location. The elimination of additional devices and manual checks leads to faster picking times and consistently high quality, especially in standardized processes.
Combination of multiple picking systems
In practice, multiple picking systems are often used in parallel. Pick to Light be easily combined with other solutions such as Pick by Light, Pick by Voice scanner-based picking. Different storage areas can thus be optimally equipped without the need for a uniform system.
These hybrid approaches make it possible to use Pick to Light where visual user guidance and cost-effectiveness offer the greatest added value. At the same time, companies remain flexible to integrate additional systems as needed.
Begriffseinordnung für Pick to Light und Pick by Light
Die Begriffe Pick to Light und Pick by Light werden im allgemeinen Sprachgebrauch häufig synonym verwendet und beschreiben dasselbe visuelle Funktionsprinzip der beleglosen Kommissionierung mit lichtgestützten Anzeigen am Lagerplatz.
At LUCA, both terms are deliberately used to clearly classify the further development and characteristics of a common system —not to distinguish between different systems.
- Pick by Light bezeichnet bei LUCA eine etablierte Display- und Systemlinie innerhalb dieses Ansatzes, die sich durch eine hochwertige Architektur und umfangreiche Funktionen und Optionen auszeichnet. Erfahren Sie mehr über unser Pick-by-Light-System.
- At LUCA, Pick-to-Light stands for a modular, series-based picking system that is designed to be economical for standardized picking processes and is continuously being further developed.
Beide Bezeichnungen basieren auf derselben LUCA-Softwareplattform und sind voll kompatibel. Alle Displays können gemeinsam in hybriden Systemlandschaften betrieben und flexibel kombiniert werden.
General economic definitions can be found at Wikipedia.
Frequently asked questions about Pick to Light FAQ)
Basics of the Pick to Light
What is Pick to Light?
Pick to Light is a light-based picking method in which LED indicators directly at the storage compartment show the picking location and quantity. Employees are guided visually and confirm the pick using a button or sensor. The method reduces error rates and increases efficiency in warehousing and production.
How does a Pick to Light work in order picking?
A Pick to Light controls picking orders via light signals with LED displays at the respective storage compartment. Once an order has been released, the display shows the quantity to be picked. The employee picks the goods, confirms the pick, and the system immediately processes the feedback. This results in visually guided, structured, and error-free picking.
For which processes is Pick to Light suitable?
Pick to Light particularly Pick to Light for processes with high picking frequencies, recurring orders, and clearly defined warehouse structures. Typical areas of application include serial picking, production supply, assembly workstations, and e-commerce and spare parts warehouses with high throughput.
Cost-effectiveness & ROI
When is it economically viable to use a Pick to Light ?
A Pick to Light is particularly worthwhile when there is a high volume of goods movement and low tolerance for errors. Reduced picking errors, shorter search times, and faster training of new employees result in direct cost advantages. The system can quickly pay for itself, especially when personnel costs are rising.
Why is a Pick to Light considered a particularly economical solution?
Pick to Light modular configuration with different display series, allowing investments to be tailored precisely to warehouse structure and picking volumes. Visual guidance reduces error rates in the long term while shortening throughput times. This combination increases both efficiency and cost-effectiveness.
How quickly does a Pick to Light pay for itself in practice?
The payback period depends on picking volume, error rate, and personnel costs. In environments with high picking performance, a Pick to Light can pay for itself within a few years, as efficiency gains and error reductions enable direct savings.
What factors influence the investment costs of a Pick to Light ?
The investment costs are determined by the number of storage locations, the selected display series, the integration effort, and the scope of the project. The scaling strategy—such as gradual introduction or complete implementation—also influences the budget.
Display series & system architecture
Which display series are available for a Pick to Light ?
Depending on the application, different display series can be used—from compact modules for shelf racks to powerful displays for high picking frequencies. The selection is made according to warehouse layout, article structure, and ergonomic requirements.
How is the right display series selected for a Pick to Light ?
The selection of the display series depends on picking intensity, storage density, visibility requirements, and budget. A structured analysis of the storage processes forms the basis for the optimal system design.
Can a Pick to Light be expanded or scaled in a modular fashion?
Yes, a Pick to Light has a modular design and can be expanded step by step. Additional storage zones, displays, or workstations can be integrated without completely rebuilding existing structures.
How are displays replaced or changed in a Pick to Light ?
Displays can usually be replaced on a modular basis without interrupting the entire system. Depending on the architecture, individual modules can be replaced quickly, which minimizes maintenance times and increases operational reliability.
Integration, IT, and technical interfaces
How is a Pick to Light integrated into existing WMS or ERP systems?
A Pick to Light is connected to existing WMS or ERP systems via standardized interfaces. Communication takes place in real time, so that order data, pick confirmations, and inventory changes are synchronized directly.
What technical interfaces does a Pick to Light have?
Typical interfaces include: RESTful API, TCP/IP, UDP, CSV files, databases, RFC, iDOC, etc., as well as standardized data formats for communication with higher-level IT systems. This allows the Pick to Light to be flexibly integrated into existing IT landscapes. LUCA also develops customer-specific interfaces.
Is it necessary to change IT systems in order to introduce a Pick to Light ?
As a rule, no system change is necessary. Pick to Light can be integrated into existing IT infrastructures, provided that suitable interfaces are available.
What data does a Pick to Light process in real time?
The system processes order data, withdrawal quantities, pick confirmations, and inventory changes in real time. This results in transparent processes and up-to-date inventory levels.
Areas of application & combinations
Is Pick to Light suitable for production and assembly environments?
Yes, Pick to Light structured material provision in production and assembly. Visual guidance reduces missing parts and ensures clear process steps in the workplace.
Is a Pick to Light suitable for e-commerce and mail order warehouses?
Especially in e-commerce environments with high order frequencies, a Pick to Light can significantly increase picking performance and reduce picking errors.
Can a Pick to Light be combined with other picking systems?
Yes, Pick to Light be combined with other picking methods on a zone-by-zone basis, for example, in the case of different article structures or process requirements. Integration takes place in the powerful, real-time LUCA software.
Delimitation & Classification
How does Pick to Light differ Pick to Light the classic Pick-by-Light principle?
The pick-by-light principle describes light-assisted picking in general. Pick to Light , on the other hand, Pick to Light for the concrete, modular system implementation with specific display series and integration solutions.
When does a Pick to Light make sense compared to other picking methods?
A Pick to Light is particularly useful for clearly structured warehouse processes, high picking density, and requirements for low error rates and transparent processes.
Project planning & implementation
How does the introduction of a Pick to Light work in a company?
The introduction typically takes place in several phases: analysis of warehouse processes, system selection, IT integration, pilot operation, and gradual rollout.
How long does it take to implement a Pick to Light ?
The implementation time depends on the scope of the project, warehouse size, and integration effort. In clearly structured environments, the introduction can be carried out step by step to minimize operational disruptions. Implementation usually takes between 10 and 14 weeks.
Free online consultation
Personal consultation on the planning and implementation of pick-to-light systems for warehouses, production, intralogistics, and assembly.
Our experts will assist you with:
- Selection of suitable pick-to-light displays
- Analysis and optimization of operational processes
- Integration into existing WMS and ERP systems
Our approach:
"A good solution requires a good idea—not just technology."
Founder & CEO of LUCA Logistic Solutions
Sławomir Skarbecki
