There are many ways to use a Pick-to-Light system. In a fast-moving line, lights are installed on racks and pickers use the following process:
Pick-to-Light Order Picking Process (Racks):
- The picker starts a picklist (list of inventory items to pick in order to fill one or more orders–typically started with a barcode scan).
- The pick-to-Light hardware lights up with the quantity to pick.
- The picker presses the button to acknowledge each pick.
- The picker repeats the process until the picklist is complete.
Alternatively, many warehouses cannot afford to install pick lights on all their racks and choose, instead, to batch pick using picking carts outfitted with pick-to-light hardware.
Batch Picking with Pick-to-Light (Single Lighted System):
- The order picker is directed to a stock location.
- (Optional) The picker scans a barcode at that location.
- The picker picks an item from the location.
- The Put-to-Light device on the cart illuminates to show which tote the item should be placed in.
Picking carts optimize batch picking by reducing the pickers total travel distance while increasing his/her accuracy and picking rates. Batch picked orders are often taken to put-walls for order sortation, packing, and shipping.