Where is Pick-to-Light used?

Pick-to-Light is very versatile and is used wherever simple information needs to be displayed directly on storage compartments or on machines. The operator can make the appropriate entries via various keys on the Pick-to-Light compartment displays.

eCommerce: Picking and replenishment in the dispatch warehouse

In a dispatch warehouse, the Pick to Light is mostly used for picking the A or B items. This fast picking method brings enormous advantages for performance and quality. The use of a conveyor system in combination with a material flow system further optimises the overall system.

When using the conveyor system, the shipping cartons automatically travel to the individual picking zones. The order is only activated and the appropriate displays light up after ejection. The strong LED signals the position from a great distance. Whereby the displays show the removal quantity directly. Afterwards, the employee acknowledges the removal with a button directly on the display.

If the stock level at the storage compartment does not match, the employee can enter a message for a shortage directly at the display.

In addition to picking, the Pick-to-Light system is also used very successfully to support replenishment. Simple "put-to-light" displays are mounted on the individual replenishment channels in a shelf. When the replenishment orders are activated, the corresponding display lights up. The employee is guided directly to the correct storage compartment. Acknowledgement is done via the button on the display or with the help of a scanner.

Automotive: Supermarket sequencing of baskets and JIT racks

Pick to Light plays a very large and decisive role in the preparation of assembly as shopping baskets and JIT racks in an automotive plant. The large number of models and variants make it impossible to store the car parts directly on the assembly line for reasons of space. For this reason, the car parts are also stored and "retrieved" in neighbouring halls or even at remote service providers. These storage areas are often called supermarkets (SuMA).

The assembly line of an automotive plant must be supplied 100% without errors and at the right time.

The preparation of car parts in the supermarkets is called sequencing. We will soon publish a separate article about sequencing in car production itself. Stay tuned ...

Our systems and the LUCA-Server are specially developed for customers with high quality demands and are perfectly suited for trouble-free continuous use. The Quick-Click-System enables a quick and easy conversion of the system. This means that the requirements for changing car parts (alternative parts) are met without any problems.

Production: assembly stations, set formation and machine placement

In production, the system can be used in a particularly versatile way. Not only one, but several product variants are often assembled at an assembly table or assembly workstation. The components are usually provided at the assembly table in small or larger containers and cartons. A large number of product variants, as well as similar and confusable components, can lead to problems with quality and performance. For this, the Pick to Light can be used very well as an aid.

After activating the orders, the corresponding displays light up directly on the components. The entire assembly process is controlled by an existing system or by our LUCA-Server . Not only the access to the components is important here, but also the correct sequence of assembly. It is very important that the system supports the employee and, if possible, corrects any mistakes (PokaYoke). Additional sensors on the displays monitor the activities and immediately report errors in case of any mix-ups.

Pick to Light can also be used very well for set building and machine placement. However, these applications are very versatile and require precise process planning. You can find out more about this in the article "How to plan a Pick-to-Light system". Please do not hesitate to contact us if you have any questions.


The Pick to Light systems can be used in many industries. However, the objectives are different in each industry. All of these tasks can be solved with our flexible LUCA-Server . The most important thing is correct planning. We are happy to support you here. Contact us and learn more about this.

Many years of experience in paperless order picking