Assembly workstations

Mounting with Pick-to-Light

Pick-to-Light optimally supports assembly at an assembly table, minimises errors, increases the quality and performance of the employees. Freely configurable with many additional options. Connection to SAP or other systems possible.

Pick-to-Light Assembly
This assembly workstation saves a lot of time and money.
Lead, support and control in a targeted way


Innovative workplaces

How does Pick-to-Light support assembly?

  1. The assembly instruction is read in at a scanner.
  2. The Pick-to-Light displays light up for the first assembly step and show the quantities directly on the containers.
  3. The fitter removes the parts and confirms the assembly on the push button.
  4. When all steps have been confirmed, the assembly is complete.
Upgrade your existing assembly tables.
optimise your assembly

Which Pick-to-Light displays are used for mounting?

Tray displays

If the number of components in the assembly instruction always = 1, the display LED with push-button is used:

PTF-L-6 - Pick-to-Light Module without display. LED and button only.
PTF-L-6: Pick-to-Light Display without quantity display

If several components have to be removed from a compartment according to the assembly instructions, then the standard display with 3-digit numerical display is used:

PTF-3N-4 Pick-to-Light Display with three-digit display and buttons
PTF-3N-4: Pick-to-Light Displays with quantity display

The compartment displays are mounted directly above or below the containers. The removal from the individual compartments is acknowledged directly at the displays. Each mounting step is acknowledged on a central button or the info display.

Info displays

Detailed information about the assembly process is shown to the employee on a central information display:

PTF-ZCTRL2 innovative Pick-to-Light Conroller and display with touch screen
PTF-ZCTRL2: as info display

If screens are used at the table, the info display is not required.

You will find a complete list of possible displays in the article:

Pick-to-Light Hardware

Option: Screens at the assembly station

If the assembly is very complex and the employee needs to see additional assembly instructions, building instructions, CAD drawings or pictures, screens are installed at his assembly station.

Assembly station
Assembly station with screens

The positions of the screens are always very individual and depend on the ergonomics of the assembly workplace. Various tools, test 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 the assembly

Optionally, each display can be equipped with a sensor for automatic access monitoring.

Mounting with sensors
Assembly workstation with Pick-to-Light sensors

Only when the employee has reached into the compartment is it possible to acknowledge with the button.

The sensor increases the quality of the collection.

If the number of pieces = 1, the acknowledgement is automatic. For other quantities, the withdrawal is acknowledged individually or centrally, but only if the active sensors have registered the accesses correctly.

If the staff member reaches into the wrong compartment, an error message and signal tone will be emitted.

Simple configuration of the assembly steps
quickly and without IT knowledge

Configuration of the assembly stations

If the connection to a production system is not available, the individual assembly steps must be configured manually.

  1. A special "Setup" barcode is read in to start the configuration.
  2. The unique barcode is then scanned to identify the assembly list.
  3. The info display shows the text "Step 1". The +/- keys help to select the steps. For each step, the configured Pick-to-Light displays on the compartments light up.
  4. The acknowledgement button of the compartment display switches the individual displays on and off.
  5. The +/- buttons can be used to set the piece counts directly on the tray.
  6. Once everything is configured, the barcode "Save" is read in and the configuration is saved.

The configuration is very simple and requires no IT knowledge. The two special barcodes ("Setup" and "Save") are available to the installation manager.

Connection to a production system

A system-side connection to SAP or to another production system is possible without any problems, but requires some coordination and possible customer-specific software adjustments.

Too many variants in the assembly?
Dynamic containers with Pick-by-Frame®

Flexibility through dynamic containers

In some situations, a lot of different parts have to be provided at the table, depending on the assembly needs and the assembly step. However, the space at an assembly table is very limited. The innovative Pick-by-Frame-System® can be used as a solution for this.

First, the required containers are picked on a picking trolley in a picking warehouse.

Pick-by-Frame and the picking trolley

For this purpose, a moving construction (Pick-by-Frame®) with mobile Pick-to-Light displays is docked to the trolley. The system guides the picker to the storage locations in the warehouse and assists him in distributing the components into the bins. The trolley is clearly identified and managed by the production system.

Picking trolley with Pick-by-Frame

When the picking trolley is ready, it is placed on a frame at the assembly station matching the assembly list. The trolley is registered at the table by its barcode or RFID. Only when the dynamic containers are correctly positioned does the assembly start.

Assembly station with overview
Flexibly adaptable to any assembly table.
System without borders


Which assembly tables can be equipped with Pick-to-Light ?

Any assembly with bins or boxes can be retrofitted. The displays can be attached to any mounting location. If the compartments are very small, the small displays of the PTF-S series can be used.

How many Pick-to-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 installation site. However, the workplace should be set up clearly and ergonomically. 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 work without any connection to a higher-level system. The configuration of the assembly steps is then done manually and does not require any special IT knowledge.

Many years of experience in paperless order picking