Pick to Light Systeme
Pick to Light ist ein belegloses, lichtgestütztes Kommissioniersystem, bei dem Mitarbeitende über visuelle Signale von Fachanzeigen direkt zum richtigen Lagerplatz geführt werden.
- Visuelle Führung mit Pick-to-Light-Fachanzeigen direkt am Lagerplatz
- Display of withdrawal location and quantity via LED
- Echtzeit-Rückmeldung über Quittiertaste an WMS- und ERP-Systeme
- Scalable pick-to-light architecture for warehousing, production, and assembly
Die Pick-to-Light-Systeme von LUCA kombinieren Displays, Controller und Software zu einer modularen, skalierbaren und modernen Lösung für Lagerlogistik, Produktionsversorgung und E-Commerce.
What is Pick to Light?
Pick to Light refers to a light-guided picking system in which LED displays located directly at the storage bin indicate the picking location and the quantity to be picked. Employees are guided visually and confirm the pick using a button or sensor.
A pick-to-light system consists of displays, controllers, and software, and visually guides employees through the picking process. Pick confirmations and inventory changes are reported back to WMS or ERP systems in real time.
Pick-to-light systems are used in particular in warehouse logistics, production supply, and e-commerce warehouses, where speed, process reliability, and scalability are critical.
How does Pick to Light work?
Pick to Light unterstützt den Kommissionierungsprozess durch eine direkte visuelle Benutzerführung mit Mengenanzeigen am Lagerplatz der Kommissionierregale. Die Steuerung erfolgt zentral über das Warehouse-Management-System oder das ERP-System. Pickaufträge werden in Echtzeit an das Pick-to-Light-System als Pickliste übertragen, die den Mitarbeitenden Schritt für Schritt durch den Kommissioniervorgang führen. Dadurch entfallen Suchzeiten, Medienbrüche, manuelle Prüfungen und alles wird schnell kommissioniert.
The Pick to Light system Pick to Light intentionally designed to be simple in order to ensure high process reliability and short training times.
The Pick to Light Picking Process
The picking process begins with the transmission of a picking order from the warehouse management system. Scanners, RFID readers, or conveyor signals can also be used to trigger these requests. As soon as the order is initiated, the system activates the corresponding pick-to-light displays. A light signal (large LED) indicates the correct storage location to the employee, while the display shows the quantity to be picked.
The picker removes the displayed quantity and confirms the pick directly using the confirmation button on the display. In the Follow-Me method, the next picking location is only activated automatically at that point. This sequential process ensures clear, intuitive user guidance and minimizes picking errors, as the focus is always on the currently relevant storage location, and it also allows multiple employees (multi-user picking) to work simultaneously (multiple LED colors).
Acknowledgment, Feedback, and Process Reliability
Nach der Entnahme bestätigt der Mitarbeitende den Pick über einen Quittierungstaster, Korrekturtasten 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 und alles ist schnell kommissioniert.
Additional security measures such as multiple confirmations, validity checks, or visual feedback further enhance process reliability. Errors are detected early and can be corrected immediately before they affect downstream processes.
Systemstruktur der Pick-to-Light-Systeme
A pick-to-light system consists of several coordinated components that work together to enable an efficient and error-free picking process. The system has a modular design 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: Displays at the storage location that show quantities, picking information, and status messages.
- Pick-to-Light controllers: Control communication between the displays and the central software.
- Mounting and cabling systems: For flexible installation on shelves, cable trays, or workstations.
- Core software: For managing picking orders, process logic, and system integration.
- Interfaces: Integration with warehouse management systems (WMS), ERP systems, or host systems.
Display-Serien der Pick-to-Light-Systeme
Pick-to-light displays are the core hardware of a pick-to-light system and provide visual guidance to employees during picking processes.
Black-Line
The Black-Line the latest series of pick-to-light displays and has been specifically designed to be cost-effective for standardized picking processes in logistics, assembly, and production.
White-Line
The White-Line a versatile pick-to-light display series offering numerous display variants and different display formats. It is particularly well-suited for applications with varying process requirements that call for flexible displays and customizable configurations.
Mini-Line
The Mini-Line a compact pick-to-light display series designed for space-saving solutions in narrow storage bays and workstations. It is particularly well-suited for standardized picking processes in confined spaces and wherever clear visual guidance is required in limited space.
Advantages of Pick-to-Light Systems
The Pick-to-Light system offers numerous benefits for companies looking to make their picking processes more efficient, safer, and more cost-effective. Direct visual guidance at the storage location minimizes the risk of manual errors and standardizes processes. At the same time, the use of cost-optimized display hardware enables a cost-effective implementation of visual picking.
- High picking speed thanks to visual guidance.
- Reduction of errors and rework.
- Quick onboarding of new employees.
- High process reliability with consistent quality.
- Scalability for warehouses of various sizes.
Reduced error rate through visual user guidance
Einer der größten Vorteile von Pick to Light ist die deutliche Reduktion von Pickfehlern durch beleglose Kommissionierung. Lichtsignale und Displays führen den Mitarbeitenden eindeutig zum richtigen Lagerplatz und zeigen die korrekte Entnahmemenge an. Fehlinterpretationen, wie sie bei papierbasierten Listen oder manuellen Scans auftreten können, werden dadurch weitgehend vermieden.
The clear visual guidance ensures consistently high picking quality, especially during periods of high picking volume or when staff rotate. Errors are detected early and can be corrected immediately where they occur.
Increasing picking efficiency
Pick to Light beschleunigt den Kommissionierungsprozess, da Suchzeiten entfallen und der Fokus stets auf dem aktuell relevanten Pickplatz liegt. Mitarbeitende folgen einer klaren, sequenziellen Benutzerführung, die unnötige Wege und Unterbrechungen reduziert.
Automating feedback to the higher-level system optimizes the entire process flow. In practice, this enables significantly higher picking performance—especially for recurring orders and standardized processes.
Ergonomics, ease of use, and a short learning curve
Pick-to-light systems are intuitive to use and do not require extensive training. New employees can become productive quickly, as the visual guidance is language-independent and does not require complex input.
Pick to Light also offers Pick to Light from an ergonomic perspective. Eliminating the need for handheld scanners or paper reduces physical strain and makes daily work easier. This contributes to greater employee acceptance and consistent process quality.
Applications of Pick to Light
Pick to Light for a wide range of warehousing and picking processes that require fast, low-error, and cost-effective order fulfillment. The system truly shines in areas with recurring picks, clearly defined storage locations, and high picking frequencies. Thanks to its modular display hardware, Pick to Light can be Pick to Light adapted to different warehouse types and process requirements.
Pick to Light Shelving and Small Parts Warehouses
In shelf and small-parts warehouses, Pick to Light significantly Pick to Light search times. The visual indicator located directly at the storage bin reliably guides the picker to the correct picking location and clearly displays the required quantity. This enables consistent picking performance even when dealing with a wide variety of items.
Besonders bei manueller Kommissionierung (am Regalen oder Kommissionierwagen) mit mit hoher Wiederholrate bietet Pick to Light einen klaren Vorteil gegenüber papier- oder scannerbasierten Prozessen. Neue Mitarbeitende können schnell eingearbeitet werden, da die Benutzerführung intuitiv und sprachenunabhängig ist.
Pick to Light Assembly
An Montage- und Arbeitsplätzen wird Pick-to-Light eingesetzt, um Mitarbeitende Schritt für Schritt durch definierte Entnahme-, Bereitstellungs- und Montageprozesse zu führen. Dies unterstützt gleichbleibende Abläufe und erleichtert die Einarbeitung neuer Mitarbeitender.
Pick to Light Production Supply
Process reliability plays a central role in production logistics. Pick to Light the error-free delivery of materials, assemblies, or components directly to the production line. Visual guidance helps prevent incorrect picks, which could lead to production interruptions or rework.
In just-in-time or just-in-sequence processes in particular, Pick to Light stabilize material flows and reliably ensure a steady supply to production. 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 fulfillment, short turnaround times and high flexibility are crucial. Pick to Light fast order picking even when order volumes fluctuate significantly. Seasonal peaks can be easily managed by using additional displays or temporary storage areas.
Even in spare parts warehouses with a wide variety of items, Pick to Light helps Pick to Light error-free Pick to Light . The clear visual guidance reduces picking errors and ensures high delivery quality, which is particularly important in the service and after-sales sectors.
Integration with WMS and ERP systems
The integration of Pick to Light existing IT environments is seamless and requires no major changes to existing systems. Pick-to-Light systems are designed to complement, rather than replace, existing warehouse processes. This allows proven workflows to remain in place while leveraging the benefits of visual picking.
A particular focus is placed on seamless integration with warehouse management systems (WMS) and ERP systems to ensure a continuous, uninterrupted flow of information.
Integration with WMS and ERP systems
Pick to Light directly integrated with the existing WMS or ERP system. Order data, storage location information, and confirmation data are exchanged via standardized interfaces or middleware. This ensures that picking orders are transmitted to the Pick-to-Light displays in real time.
The system logic remains entirely within the master system. Pick to Light as the execution system for visual user guidance and does not interfere with the existing process control. This simplifies integration and significantly reduces the implementation effort.
Integration without changing systems
A key advantage of Pick to Light that it can be implemented without changing or adapting the existing IT infrastructure. Companies do not need to replace or make major changes to their WMS or ERP systems. Existing processes are simply supplemented with a visual component.
This approach protects existing investments and allows for a phased rollout. Individual storage areas or picking zones can be equipped with pick-to-light displays on a targeted basis without disrupting overall operations.
Real-time data, transparency, and monitoring
Real-time confirmation of all picking operations provides a high level of transparency regarding current order status and inventory levels. Every confirmation on the display is immediately reported back to the host system and processed there.
This transparency enables effective monitoring of picking processes. Bottlenecks, delays, or sources of error can be identified early on and addressed in a targeted manner. Pick to Light thus Pick to Light not only operational picking but also the continuous optimization of warehouse processes.
Planning and Design of a Pick-to-Light System
The successful implementation of a pick-to-light system begins with structured planning. The goal 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 a smooth implementation.
Careful planning ensures that Pick to Light is used Pick to Light where it is most effective.
Analysis of Warehouse Structure and Processes
The planning process begins with an analysis of the existing warehouse layout and picking processes. Key factors include the number of storage locations, picking frequency, product mix, and employee walking routes. Seasonal fluctuations and future growth scenarios are also taken into account.
This analysis serves as the basis for determining which storage areas are Pick to Light for Pick to Light and how the displays should be optimally positioned. The goal is to facilitate efficient user guidance and minimize unnecessary movements.
Choosing the Right Display Series
The appropriate pick-to-light displays are selected based on the process analysis. Factors such as display size, amount of information, mounting method, and operating concept play a key role in this process. Different warehouse areas may require different display series to meet their specific requirements.
Choosing the right display hardware is crucial to the system's cost-effectiveness and user acceptance. Pick to Light you to tailor the system's configuration specifically to its intended use.
Phased rollout and pilot operation
To minimize risks, Pick to Light is Pick to Light implemented in phases. The system can be tested and optimized under real-world conditions in a pilot area. The lessons learned from the pilot operation are then incorporated into the rollout to other warehouse areas.
This approach makes it easier for employees to accept the system and allows for adjustments to be made before the system is fully rolled out. At the same time, day-to-day operations remain stable during the implementation.
Pick to Light Use at International Industrial Companies
LUCA's pick-to-light systems are used in warehouses, production facilities, and distribution centers around the world. Companies in the automotive, retail, electronics, and consumer goods industries use Pick to Light improve efficiency, process reliability, and transparency.
LUCA implements pick-to-light systems worldwide and helps companies optimize their picking processes in a cost-effective and scalable manner. You can find additional international pick-to-light case studies on our case studies 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
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 % |
| Orientation period | Several days | A few hours |
| Process reliability | Depending on experience | System-guided |
Pick to Light designed to implement visual picking in a cost-effective manner. By using cost-optimized displays, investments can be managed strategically without sacrificing the benefits of the system. Cost-effectiveness stems not only from the initial purchase price but, above all, from the long-term savings potential during ongoing operations.
A properly designed pick-to-light system pays for itself quickly in many applications.
Capital expenditures and cost structure
The investment costs for a pick-to-light system depend largely on the number of storage locations, the selected display series, and the desired level of equipment. Thanks to the cost-optimized hardware, the initial costs are lower compared to traditional installations.
Another advantage is the modular cost structure. Companies can implement Pick to Light and tailor their investments to their actual needs. This makes the financial burden predictable and scalable.
Potential savings through error reduction and increased efficiency
A key economic benefit 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 improves, which has a positive impact on customer satisfaction and service levels.
In addition, visual 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 labor costs.
Scalability and investment security
Pick to Light a high degree of investment security, as the system can be flexibly expanded. 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 cost-effective Pick to Light as demands grow. Companies are not investing in a rigid solution, but in a system that grows alongside the warehouse and its processes.
ROI for Pick to Light
A simplified example calculation can help assess the cost-effectiveness of a pick-to-light system. The actual figures always depend on the specific process, product structure, and order volume (see left).
In many applications, higher picking performance, reduced error costs, and shorter training times mean that a pick-to-light system pays for itself in a short period of time.
The potential savings in your specific process can be identified through a personalized consultation.
Pick to Light . Pick-by-Light
Pick to Light Both Pick to Light and Pick by Light refer to light-guided picking, but they differ in their application and system complexity.
Pick by Light beschreibt das grundlegende Prinzip der visuellen Führung im Kommissionierprozess als Kommissionierverfahren. Mitarbeitende werden über Displays oder LED-Anzeigen direkt zum richtigen Lagerfach geführt und bestätigen die Entnahme per Taster oder Sensor.
Pick to Light is, on the other hand, frequently used to describe the specific technical implementation of this principle. This includes modular displays, controllers, software, interfaces to WMS and ERP systems, as well as various display series for different warehouse and production requirements.
While "Pick by Light" is the established industry term for light-guided picking, Pick to Light on modern, scalable, and cost-effective system architectures for new projects and the expansion of existing facilities.
Pick to Light to Other Picking Systems
In intralogistics, companies have a variety of picking systems to choose from. The most suitable solution depends on process requirements, warehouse layout, and economic conditions. Pick to Light a visual, hardware-based system that is particularly effective for repetitive picking tasks and clearly defined storage locations.
Comparing it with other systems helps to better understand its 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 well-suited for large-scale warehouses with long walking distances and hands-free operations. However, Pick by Voice is Pick by Voice dependent on voice quality, ambient noise, and the amount of training required.
Pick to Light , is completely language-independent. The visual user guidance works reliably even in noisy environments and requires only minimal training. Especially for repetitive picking tasks with high cycle rates, Pick to Light offers greater Pick to Light and clearer user guidance.
Pick to Light . Scanner-Based Picking
Scanner-based picking is widely used and highly flexible. However, employees must actively scan items, read displays, and interpret information. This increases the number of manual steps and can lead to fatigue or errors when picking frequencies are high.
Pick to Light this complexity by displaying all relevant information directly at the storage location. Eliminating the need for additional devices and manual checks results in faster picking times and consistently high quality, especially in standardized processes.
Combination of multiple picking systems
In practice, multiple techniques are often used in parallel for picking systems. Pick to Light be easily combined with other LUCA systems. This allows different warehouse areas to be optimally equipped without being constrained by a single system.
These hybrid approaches make it possible to deploy Pick to Light where visual guidance and cost-effectiveness offer the greatest value. At the same time, companies remain flexible enough to integrate additional systems as needed.
Frequently Asked Questions About Pick to Light FAQ)
Basics of Pick to Light
What is Pick to Light?
Pick to Light a light-guided picking system in which LED displays located directly at the storage bin indicate the picking location and the quantity to be picked.
A Pick-to-Light system consists of displays, controllers, and software and visually guides employees through the picking process. Picks are confirmed via a button or sensor and reported back to WMS or ERP systems in real time.
Unlike the basic Pick-by-Light principle, Pick to Light describes Pick to Light specific technical implementation of the system for scalable warehouse and production processes.
How does a Pick to Light work in order picking?
A Pick to Light controls picking orders using light signals from LED displays located at each storage bin. Once an order is released, the display shows the quantity to be picked. The employee retrieves the item, confirms the pick, and the system immediately processes the confirmation. This results in a visually guided, structured, and low-error picking process.
For which processes is Pick to Light well-suited?
Pick to Light particularly Pick to Light for processes involving high picking frequencies, recurring orders, and clearly defined warehouse layouts. Typical applications include batch picking, production supply, assembly workstations, and high-throughput e-commerce and spare parts warehouses.
Cost-Effectiveness & ROI
When is it economically viable to use a Pick to Light ?
A Pick to Light is particularly beneficial when there is high order volume and low tolerance for errors. It delivers direct cost savings through fewer picking errors, shorter search times, and faster training of new employees. Especially in the face of rising labor costs, the system can quickly pay for itself.
Why is a Pick to Light considered a particularly cost-effective solution?
Pick to Light modular configurations using different display series, enabling investments to be tailored precisely to the warehouse layout and picking volume. Visual guidance significantly reduces error rates while shortening cycle times. This combination boosts 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 rates, and labor costs. In environments with high picking throughput, a Pick to Light can pay for itself within a few years, as increased efficiency and reduced errors lead to direct cost 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 a phased rollout or a full-scale implementation—also affects 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—ranging from compact modules for shelf racks to high-performance displays for high picking frequencies. The selection is based on the warehouse layout, product structure, and ergonomic requirements.
How do you choose the right display series for a Pick to Light ?
The choice of display series depends on picking intensity, storage density, visibility requirements, and budget. A structured analysis of warehouse processes forms the basis for 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 in stages. Additional storage zones, displays, or workstations can be integrated without having to completely overhaul existing structures.
How are displays replaced or changed in a Pick to Light ?
Displays can generally be replaced on a modular basis without interrupting the entire system. Depending on the architecture, individual modules can be replaced quickly, which minimizes downtime and enhances operational reliability.
Integration, IT & Technical Interfaces
How is a Pick to Light integrated into existing WMS or ERP systems?
A Pick to Light is integrated with existing WMS or ERP systems via standardized interfaces. Communication takes place in real time, ensuring that order data, pick confirmations, and inventory changes are synchronized immediately.
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 communicating with higher-level IT systems. This allows the Pick to Light to be seamlessly integrated into existing IT environments. LUCA also develops custom interfaces.
Does implementing a Pick to Light require a change in IT systems?
Generally, 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, picking quantities, picking confirmations, and inventory changes in real time. This ensures transparent processes and up-to-date inventory levels.
Applications & Combinations
Is Pick to Light suitable for production and assembly environments?
Yes, Pick to Light structured material staging in production and assembly. The visual guidance reduces missing parts and ensures clear process steps at the workstation.
Is a Pick to Light suitable for e-commerce and fulfillment warehouses?
Especially in e-commerce environments with a high volume of orders, a Pick to Light can significantly boost 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 when dealing with different product structures or process requirements. Integration takes place within the powerful, real-time-capable LUCA software.
Definition & Classification
How does Pick to Light differ Pick to Light the traditional pick-by-light principle?
The "pick-by-light" principle describes light-guided order picking in general. Pick to Light ," on the other hand, Pick to Light to the specific, modular implementation of the system using specific display series and integration solutions.
When is a Pick to Light a better choice than other picking methods?
A Pick to Light is particularly useful for clearly structured warehouse processes, high picking volumes, and requirements for low error rates and transparent workflows.
Project Planning & Implementation
What is the process for implementing a Pick to Light in a company?
The implementation typically takes place in several phases: analysis of warehouse processes, system selection, IT integration, pilot operation, and phased rollout.
How long does it take to implement a Pick to Light ?
The implementation timeline depends on the scope of the project, the size of the warehouse, and the complexity of the integration. In well-structured environments, the rollout can be carried out in phases to minimize operational disruptions. Implementation typically takes between 10 and 14 weeks.
Free Online Consultation
Personalized consulting on the planning and implementation of pick-to-light systems for warehousing, production, intralogistics, and assembly.
Our experts can assist you with:
- Selecting Suitable Pick-to-Light Displays
- Analysis and Optimization of Business Processes
- Integration with existing WMS and ERP systems
Our approach:
“A good solution requires a good idea—not just the technology.”
Founder & CEO of LUCA Logistic Solutions
Sławomir Skarbecki