The operation of a Pick-to-Light system is very important for the order picker, his performance and quality. In the picking process, the employee must be guided safely and quickly to his storage location (storage compartment) using the compartment displays. The picking errors must be reduced to an absolute minimum.
The requirements for optimum access to a storage compartment vary greatly in the process. The order picker should quickly follow the light signal at the storage location, read the quantities on the quantity display clearly and carry out the confirmation safely (short learning and search time). There is no picking list and the picker has his hands free. This is a great advantage of the paperless picking system.
Standard procedure for Pick-to-Light
LUCA offers standard packages in which the picking process in a warehouse already meets 80% of all requirements. The aim is to minimize the error rate and speed up the picking process.
Very often the requirements for the Pick-to-Light system are very specific. We integrate different solutions and build the process also customer specific. The entire logical data processing is handled by our LUCA-Server.
We now explain the simple process of a Pick-to-Light order picking:
Start of picking
How can the Pick-to-Light start the correct orders? Can the completeness of the last order be checked?
Basically there are two different start methods in the process:
- Start via a document with barcode
- Paperless picking (FIFO or external trigger)
In the process the start can be arranged in different ways.
If the cartons or containers are marked with a barcode (1D or 2D), stationary or mobile scanners can be used in the process for Pick-to-Light activation (scan). In this case, the displays can also be activated via the delivery note or invoice. RFID technology is also supported.
With paperless systems, the orders usually start automatically, either from a data buffer or by automatic ejection of the containers via a conveyor system. In both cases, it LUCA-Server monitors the individual processes and ensures the appropriate quality. With some solutions, the start of the next order will only be possible after the previous order has been completely completed. If an error occurs here, the system generates an error message.
Procedure at the Pick-to-Light trade advertisements. Simultaneous, sequential or page by page?
If you have already started picking, the displays on the shelves must now light up. But how should they light up best? All together, one after the other, first one and then the other side of a shelf aisle?
With different methods we achieve different goals. As a planner, you must have a good understanding of the exact procedure at the storage compartment and choose the correct method, taking cognitive ergonomics into account. This point is very important when creating the systems. Take your time to find an optimal solution.
Although a Pick-to-Light display is very simple in principle, the process can be very different. The control for this is done by a software module on the LUCA-Server. If necessary, we also use different techniques simultaneously.
In simple systems, all displays and signal lamps in a picking zone light up simultaneously. This is also the standard. The order in which the goods are picked is not defined. In other cases we create a picking route and control the picks sequentially.
Confirmation of withdrawal and end of order
When all articles have been picked, the picker acknowledges the removal at the compartment with the acknowledgement button. If the quantity is not correct, the correction keys (+/-) can be used. The confirmation of the pick triggers a feedback to the superordinate Warehouse Management System. There the stock changes are carried out in real time.
Sometimes put-to-light ads are used Multi-Order-Picking to support the put process in logistics. However, we describe this topic separately.
More information: " Pick-to-Light - Picking method with compartment displays"