Assembly workstations

Mounting with Pick-to-Light

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

Pick-to-Light Mounting
This assembly workstation saves a lot of time and money.
lead, support and control in a targeted manner


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 assembler removes the parts and confirms the assembly on the probe.
  4. When all steps are confirmed, the assembly is complete.
Upgrade your existing assembly tables.
optimize 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 pushbutton is used:

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

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

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

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

Info displays

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

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

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

You can find a total 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 monitoring of accesses.

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

Only when the employee has reached into the compartment, the acknowledgement with the pushbutton is possible.

The sensor increases the quality during removal.

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

If the employee reaches into the wrong compartment, an error message and signal tone are generated.

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

The configuration is very simple and does not require any IT knowledge. The two special barcodes ("Setup" and "Save") are available to the assembly supervisor.

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 very large number of different parts must be provided at the table, depending on the assembly requirements 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 totes are picked on a picking cart in a picking warehouse.

Pick-by-Frame and the picking cart

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

Picking cart with Pick-by-Frame

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

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 containers 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. One standard controller controls up to 150 displays. Several controllers can also be used at an assembly station. However, the workstation should be clearly arranged and ergonomically designed. 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 operate 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