Types of Pick-to-Light Systems and When to Use Them

Pick-to-Light has evolved into a family of solutions tailored to different warehouse needs. Understanding the main types helps beginners choose the right approach for their operation. Below are the most common Pick-to-Light system varieties, their typical use cases, and quick guidance on when to select each.

Shelf-mounted Pick-to-Light

• Description: Fixed light modules are attached directly to shelving or racking locations. Lights and numeric displays indicate picks at each bin or slot.
• Best for: Environments with fixed storage locations and medium-to-high pick frequencies, such as spare parts, consumer goods, and small-parts distribution.
• Why use it: Provides the fastest pick feedback and is ideal where SKUs are consistently stored in the same spot.

Tote- or Cart-based Pick-to-Light (Pick-to-Cart/Tote)

• Description: Light modules are mounted on portable carts or totes that collect picks. Lights indicate to the picker which items to add to each tote compartment.
• Best for: Batch picking and multi-order fulfillment where multiple orders are consolidated on a single cart or in several totes.
• Why use it: Streamlines multi-order picking and reduces travel by letting a picker fulfill several orders in one pass.

Wireless Pick-to-Light

• Description: Light modules communicate wirelessly with a central controller, eliminating the need for complex wiring and allowing flexible placements.
• Best for: Facilities where wiring is expensive or disruptive, temporary locations, retrofit projects, or where frequent layout changes are expected.
• Why use it: Offers lower installation disruption and scalable deployment; battery-powered options increase placement freedom.

Integral vs. Standalone Systems

• Standalone: Simple controller with minimal software, suitable for small operations that need faster picking without WMS integration.
• Integrated: Tightly connected to a Warehouse Management System (WMS) or ERP for advanced sequencing, inventory control, and reporting.
• Best for: Integrated systems are recommended for larger operations seeking real-time inventory accuracy and analytics; standalone systems suit small-to-medium operations wanting quick gains with minimal IT work.

Cabinet or Kitting Pick-to-Light

• Description: Enclosed cabinets or drawers with light modules are used for high-value or sensitive SKUs, often in assembly or kitting contexts.
• Best for: Electronics, pharmaceuticals, or any scenario needing secure storage and accurate component assembly.
• Why use it: Combines security and precision—very useful for pick-and-assemble tasks where component accuracy matters.

Zone and Wave-oriented Pick-to-Light

• Description: Systems are deployed by zones to support split-case, wave, or zone picking strategies. Pick lights activate in sequence by zone to coordinate multiple pickers.
• Best for: Large warehouses with many SKUs and high throughput where workload balancing and parallel picking are needed.
• Why use it: Allows multiple pickers to work concurrently while maintaining order accuracy and reducing travel time.

Choosing the right type — practical considerations

• Volume and SKU mix: High-volume, repeatable picks favor shelf-mounted systems; variable SKUs and changing layouts may lean toward wireless or tote-based systems.
• Space and layout: Dense shelving with fixed locations is ideal for permanent modules; open or frequently reconfigured spaces often benefit from wireless kits or cart-based options.
• Integration needs: If you require robust inventory tracking and analytics, choose a system that integrates with your WMS or ERP.
• Budget and scalability: Start with a pilot of a standalone or modular system if capital is limited; plan for future integration as volumes grow.

Alternatives and hybrids

Pick-to-Light is often compared with voice picking, RF barcode scanning, and automated conveyor/tote systems. Each has trade-offs: voice picking excels when hands-free operation is needed, RF scanning provides strong traceability, and automation reduces manual labor in very high-throughput environments. In practice, many operations mix methods—using Pick-to-Light for small-parts or kitting areas while relying on RF or conveyors for bulk and pallet handling.

Summary

There is no single "best" Pick-to-Light system—your choice depends on product type, order profiles, layout flexibility, budget, and whether you need WMS integration. For beginners, starting with a small pilot of a modular or wireless Pick-to-Light solution often reveals the fastest path to measurable productivity gains with minimal disruption.