{"id":7608,"date":"2025-06-19T07:51:22","date_gmt":"2025-06-19T05:51:22","guid":{"rendered":"https:\/\/cavea.net\/?p=7608"},"modified":"2026-09-15T14:00:03","modified_gmt":"2026-09-15T12:00:03","slug":"efficient-order-picking-with-pick-by-light-how-modern-systems-optimize-material-flow","status":"publish","type":"post","link":"https:\/\/cavea.net\/en\/blog\/technology\/efficient-order-picking-with-pick-by-light-how-modern-systems-optimize-material-flow","title":{"rendered":"Efficient order picking with Pick by Light: How modern systems optimize material flow"},"content":{"rendered":"\t\t
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How Pick by Light works and why it improves picking<\/h2>\n

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Anyone who has ever stood in a supermarket and seen a light flashing at the next available checkout knows the effect of clear, visual guidance. Without thinking twice, you are intuitively guided to where you need to go\u2014quickly, efficiently, and without mistakes. This is precisely the principle behind a proven solution in intralogistics: Pick by Light.<\/p>\n

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This is a system that controls picking in warehouses and production areas using visual signals. Instead of paper lists or mobile scanners, items are picked directly from the shelf\u2014LEDs indicate which product needs to be picked. This saves time, reduces errors, and ensures smooth operations.<\/p>\n

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The major advantage<\/strong>: material flow is accelerated, sources of error are reduced, and processes can be standardized more effectively. Companies in industries with high cycle times and low error tolerances in particular rely on visual picking systems to increase their efficiency.<\/p>\n

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In this article, we take a closer look at what Pick by Light is exactly, what a typical process looks like, which industries can benefit from its use, and what advantages the method offers compared to traditional picking systems.<\/p>\n

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What is pick-by-light and how does the system work? <\/h2>\n

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Pick by Light is a digital picking method in which shelf compartments or storage locations are equipped with light indicators. As soon as a picking order is received, the system activates a light signal at the corresponding picking location. Employees immediately recognize which item they need to pick\u2014without scanning or searching manually.<\/p>\n

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The system not only displays the storage location, but often also the quantity to be removed. After picking up the product, employees confirm the pick by pressing a button directly on the compartment. The system registers the process in real time and triggers the next step.<\/p>\n

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By using illuminated indicators, companies reduce search times, avoid mistakes and increase efficiency. At the same time, training costs for new employees are reduced, as the visual guidance is self-explanatory and quickly understood. The system ensures structure and speed in the material flow, especially when order volumes are high.<\/p>\n

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How a pick-by-light process works in practice<\/h2>\n

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A pick-by-light process follows a clear and repeatable sequence that can be easily integrated into everyday work. Companies rely on visual guidance to speed up material flow and efficiently guide employees through the picking process.<\/p>\n

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Typical sequence of a pick-by-light process:<\/p>\n

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  1. Creating Orders in the System:<\/strong>\nThe warehouse management system (WMS or ERP) creates a new picking order\u2014either automatically or manually. The order contains all relevant items.<\/li>\n

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  2. Signal at the storage location:\nAs soon as the employee starts the order, the system sends a signal to the corresponding storage bins. An indicator\u2014usually a colored LED\u2014lights up on each bin.<\/li>\n\n
  3. Picking Items:<\/strong>\nThe employee can see at a glance which item is needed and in what quantity. The employee retrieves the product and picks the required number of units.<\/li>\n

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  4. Confirmation of the Pick:<\/strong>\nThe pick is confirmed with the push of a button right at the bin. Alternatively, touchscreens can be used. The system registers the action in real time.<\/li>\n

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  5. Next Pick or Completion:<\/strong>\nEither the next bin lights up, or\u2014in the case of a single pick\u2014the order is complete. The system automatically reports the progress.<\/li>\n

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    Special Feature:\nLight-guided systems can be flexibly expanded for multi-order picking or zone-based picking. Companies can dynamically adapt their processes\u2014for example, using mobile carts with light modules or hybrid solutions combining pick-to-light and put-to-light.<\/p>\n

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    The entire process saves time, reduces manual searches, and improves the traceability of individual picks. This increases transparency in the material flow and ensures stable, scalable picking performance\u2014regardless of the order volume.<\/p>\n

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    \"Pick-by-light

    <\/p>\nEfficient order picking through visual signals directly at the storage location<\/figure>\n\n

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    Advantages of Pick by Light in order picking<\/h2>\n

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    Companies use pick-by-light systems for good reason\u2014the advantages speak for themselves. In many warehouses and production environments, this technology is replacing traditional picking methods such as paper lists or mobile scanners. The goal: faster processes, fewer errors, and a stable material flow.<\/p>\n

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    Here are the key benefits at a glance:<\/p>\n

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    1. Lower error rate during picking<\/strong>
      Thanks to visual guidance, employees pick items directly from the correct storage location. This reduces typical errors such as reaching into the wrong compartment or overlooking items. Pick by Light ensures accurate picking, especially when there is a wide variety of items.<\/li>\n

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    2. Faster processes thanks to visual support<\/strong>
      The pick-by-light display immediately shows where the next item is located \u2013 no scrolling on the scanner, no looking up on paper. This saves seconds with every pick, which quickly adds up when you have hundreds of orders a day. Picking speed increases measurably.<\/li>\n

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    3. Improved material flow and shorter throughput times<\/strong>
      A structured picking process has a direct impact on material flow. Goods flow faster from the warehouse to production or shipping. Companies benefit from shorter throughput times and more predictable processes\u2014especially in tightly scheduled supply chains.<\/li>\n

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    4. No long training period<\/strong>
      Pick-by-light systems can be operated without extensive training. New employees immediately recognize what needs to be done. This simplifies the onboarding process and makes companies more flexible in the event of seasonal fluctuations or high turnover in the warehouse.<\/li>\n

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      Scalability for growing requirements<\/strong>
      Whether for small warehouses or large logistics centers, pick-by-light solutions can be expanded on a modular basis. Companies can adapt the system to new processes or product groups without interrupting operations.<\/p>\n

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      Pick by Light offers an efficient, error-free, and scalable solution for modern picking processes. Combined with a powerful warehouse management system, the system increases productivity and ensures a smooth flow of materials\u2014even as demands grow.<\/p>\n

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      In which industries is Pick by Light used?<\/h2>\n

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      Pick by Light is versatile and can be used wherever companies need to pick items quickly, accurately, and at high speeds. The technology can be flexibly adapted to different industries, from e-commerce to manufacturing.<\/p>\n

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      Here are some typical areas of application:<\/p>\n

      Automotive and Supplier Industry<\/strong>
      In production, just-in-time logistics and absolute reliability are essential. Pick by Light supports the supply of materials to assembly lines by precisely indicating which parts are needed and in what order. This virtually eliminates errors in parts provision.<\/p>\n

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      Logistics<\/strong>
      A wide variety of items, small quantities, and high availability requirements\u2014visually guided picking solutions simplify work in complex warehouse systems. Employees find the products they\u2019re looking for faster and avoid picking the wrong items.<\/p>\n

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      Pharmaceuticals and Medical Technology<\/strong>
      This sector has strict requirements for documentation and error prevention. Digital systems with visual withdrawal indicators enable precise tracking and ensure that the correct product is dispensed in the correct quantity. At the same time, the material flow remains transparent and traceable.<\/p>\n

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      E-commerce & mail order<\/strong>
      In online retail, every minute counts: customers expect short delivery times and error-free orders. Intelligent lighting systems support the efficient picking of large quantities of items \u2013 even with frequently changing product ranges. They increase speed and accuracy, especially in multi-order picking or same-day delivery processes.<\/p>\n

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      This visually assisted order-picking method is no longer a niche product. Whether you\u2019re a manufacturing company, a logistics service provider, or an online retailer\u2014if you want to make your processes more efficient, you\u2019ll find a scalable and future-proof solution here.<\/p>\n

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      Tip:<\/strong> In this use case from ekko<\/a>, you’ll learn how a pick-by-light solution was implemented in practice\u2014including a real-world example from everyday warehouse operations.<\/p>\n

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      Pick-by-Light and Location Technology: A Sensible Combination?<\/h2>\n

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      Systems with visual picking assistance are particularly effective in stationary warehouse areas\u2014but what happens when picking carts or entire shelving units move around the room? This is where location tracking technologies come into play.<\/p>\n

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      Real-time location systems (RTLS) such as Cavea Mesh<\/a> or UWB can be used to track the location of mobile objects in a warehouse. This provides companies with additional visibility into routes, locations, and process bottlenecks.<\/p>\n

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      Why location tracking is a useful addition<\/strong><\/h4>\n

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