Pick-to-Light: How It Works for Beginners

Pick-to-Light is a simple, intuitive technology that uses illuminated indicators to direct warehouse workers to the correct storage locations and to show them how many items to pick. Imagine walking down an aisle and seeing a small light above a bin flash to tell you where to pick, with a numeric display showing the quantity. That is the essence of Pick-to-Light, and it is designed to make picking fast, accurate, and easy to learn.

At a basic level, a Pick-to-Light system has a few main components:

• Light modules mounted at pick locations such as shelves, bins, or tote lanes. These typically include a bright LED and a simple numeric display or indicator.
• Control unit or controller that sends commands to the light modules. This unit receives work instructions from warehouse software and activates the appropriate lights.
• Wiring or wireless network that connects the modules to the controller. Modern systems often use wireless or IP-enabled modules for easier installation.
• Warehouse software like a WMS or middleware. The software assigns order picks, communicates with the controller, and records confirmations when picks are completed.

How the process works in practice

1. An order or batch of orders is released by the warehouse management system to the Pick-to-Light controller.
2. The controller activates the lights at the bin locations required for that work. Each light corresponds to a SKU and a quantity.
3. The picker arrives at the pick face. The lit modules and displays indicate where to pick and how many units to take.
4. The picker confirms the pick by pressing a button on the module, tapping a nearby confirmation device, or scanning a barcode, depending on system setup. The system records the pick and advances to the next location.
5. Once all picks in the batch are complete, the items are consolidated and moved to packing or shipping.

Real example

A consumer electronics distributor uses Pick-to-Light for small, high-SKU orders. An operator opens a tote at the packing station and a series of lights along the shelf indicate the parts to put into the tote. Numeric displays show quantities like 1 or 2. The operator confirms each pick by pressing the illuminated button. The system logs every pick in real time, reducing errors and speeding up packing.

Why Pick-to-Light is beginner friendly

• Low learning curve - The system uses visual cues that are easy to understand, so new hires can be productive quickly without complex training.
• Reduced errors - Lights and quantity displays remove ambiguity that can cause mistakes with paper lists or verbal instructions.
• Faster picking - Visual guidance minimizes search time, which is valuable in high-volume operations.

Common use cases include kitting, light assembly, eCommerce order fulfillment, and pick-and-pack processes where small, fast picks dominate. Pick-to-Light excels when many picks are required per hour and when accuracy is critical.

Integration considerations for beginners

• WMS compatibility - Check whether your warehouse management system supports Pick-to-Light or whether middleware will be needed to translate instructions.
• Layout planning - Map your slot locations carefully. High-velocity SKUs should be placed in pick-to-light zones for maximum benefit.
• Scalability - Start with a pilot lane or zone before expanding. Pick-to-Light systems are modular and can grow with your needs.

Costs and ROI basics

Upfront costs include hardware, installation, and software integration. However, the ROI can be compelling for the right operations due to increased throughput, reduced errors, and lower training costs. Businesses often measure ROI by tracking picks per hour, order accuracy, and labor cost per order before and after deployment.

Limitations to be aware of

Pick-to-Light is not the best fit for bulk pallet picking or very large, loose items. It excels at piece picking, small carton picking, and put-to-light consolidation. Also, systems that require heavy wiring may be disruptive to install in existing facilities, though wireless options mitigate this.

Beginner tips

• Run a small pilot on a high-velocity SKU family to prove benefits.
• Standardize slot sizes and labels so lights and displays are visible and unambiguous.
• Train staff on confirmation procedures to ensure the system records accurate picks.
• Monitor KPIs and adjust slotting to keep the fastest-moving SKUs in Pick-to-Light zones.

In short, Pick-to-Light is a user-friendly, efficient way to speed up and simplify order picking. For beginners, it provides a highly visual, low-training solution that improves accuracy and throughput, especially in operations with many small, fast-moving picks.