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Smarter Assembly & Order Fulfilment with Pick to Light

In both manufacturing and fulfilment, speed and accuracy are critical to keeping operations efficient and customers satisfied. One proven technology that supports both environments is the Pick to Light system. By using LED indicators to guide operators to the correct parts or products, it streamlines picking, reduces errors, and keeps work flowing smoothly.

What is a Pick to Light system?

Pick to Light (PTL) is a guided picking method that uses lighted indicators and small display screens mounted on shelves, flow racks, totes or benches. When a job is released, the relevant locations light up and show the quantity to pick. The operator presses a confirm button to acknowledge the pick. That’s it, no hunting, no clipboards & minimal screen time.

Pick-to-light system

Why it Works

  • Reduced picking errors – operators select the correct item the first time, whether it’s a component for assembly or an order line for packing.
  • Faster throughput – quicker picking shortens production cycle times and accelerates order fulfilment.
  • Flexibility – easily adapts to new production lines, seasonal peaks, or changing product ranges.
  • Improved morale – simple, intuitive technology that reduces stress and supports staff productivity.
  • Lower costs – fewer mistakes, less waste, better use of warehouse or factory space, and stronger ROI.

Points to consider:

  • Training is essential – staff need to be confident using the system to unlock its full benefits.
  • Scalability matters – your system should grow with your production volumes or order demand.
  • Investment vs. returns – while the upfront cost exists, long-term efficiency gains often outweigh it.

How Pick to Light fits your operation

  • Assembly cells: Lights guide operators through bill-of-materials in the correct sequence, reducing rework.

  • Kitting: Build kits quickly with location lights and quantity prompts.

  • Packing benches: Lights identify the next order lines to add, cutting packing errors.

  • Put walls / sortation: Use “Put to Light” to sort batch-picked items into individual orders.

What to consider before you buy

Training matters – short, hands-on sessions ensure staff are confident and the benefits stick.

Scalability – choose hardware and software that can grow with volumes and SKUs.

Integration – confirm smooth links with your WMS/ERP or simple middleware.

Durability –  industrial housings, clear displays and easy field-replaceable parts.

Investment vs returns – upfront cost is offset by error reduction and labour efficiency.

Frequently Asked Questions (Q&A)

Q1: Is Pick to Light only for warehouses?
A: No. It’s just as effective on the factory floor—especially for kitting and line-side assembly.

Q2: What’s the difference between Pick to Light and Put to Light?
A: Pick to Light guides you to take items from locations. Put to Light guides you to place items into the right order slots (common on put walls and packing stations).

Q3: How accurate is it compared to paper or handheld scanners?
A: PTL removes a lot of manual lookups and typing. Most sites see a step-change in accuracy because the light shows exactly where to go and how many to pick, and a button press confirms each step.

Q4: Do we still need barcode scanning?
A: Yes you will still likely need barcode scanning, many setups combine lights for speed with barcode scans at key checkpoints (e.g. order start/finish or high-value items) for traceability.

Q5: Will it work with our WMS/ERP?
A: PTL controllers typically connect via API, middleware or simple file drops. During scoping we map your order/production data to the light logic so it stays in sync.

Q6: How long does installation take?
A: A pilot line or packing area can be fitted in days. Larger rollouts happen in phases to avoid downtime—often over a few weekends or shift gaps.

Q7: What does training look like?
A: Short on-bench sessions: 30–60 minutes for operators, half-day for supervisors. Most users are confident the same day.

Q8: What if our layout changes?
A: You can reassign lights to new SKUs or stations in software. Rails and modules are modular, so you can move or add segments easily.

Q9: Is it suitable for very small operations?
A: Yes, you can, if you wish, start with a handful of bays or benches and then expand as volumes grow.

Q10: How robust are the lights?
A: Industrial LED modules are rated for high-use environments. If a module fails it can be swapped quickly without taking the whole line down.

A simple rollout plan for Pick to Light

Process walk-through – map where errors or delays occur.

Pilot cell/bench – prove the gains on a small, safe scope.

Integration – connect to WMS/ERP or use light-controller software.

Train & go-live – operator training and supervisor dashboards.

Scale out – extend to more lines, bays or a put wall as results come in.

 

At IDC Conveyors LTD, we implement Pick to Light solutions that work seamlessly across both factory floors and fulfilment centres. From assembly stations to packing benches, we ensure the system is tailored to your workflows, so it delivers measurable results.

Forward-thinking businesses in manufacturing and fulfilment are already achieving greater efficiency, higher throughput, and reduced waste. By adopting smart technologies like Pick to Light today, you can stay competitive in an increasingly demanding market.

Head over to our Contact Us page for more information.

 

Get in touch with us today for a personalised quote or call +44 (0) 1285 770 890 for an initial consultation to discuss how we can optimise your operations.

 

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📧 sales@idc-conveyors.com

☎ +44 (0) 1285 770 890

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