{"id":7608,"date":"2025-06-19T07:51:22","date_gmt":"2025-06-19T05:51:22","guid":{"rendered":"https:\/\/cavea.net\/?p=7608"},"modified":"2025-06-19T07:51:23","modified_gmt":"2025-06-19T05:51:23","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":"\n

How Pick by Light works and why it improves picking<\/h2>\n\n

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\n

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\n

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\n

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\n

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

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\n

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\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\n

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

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\n

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

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  1. Order creation in the system:<\/strong>The warehouse management system (WMS or ERP) creates a new picking order \u2013 automatically or manually. The order contains all relevant items. <\/li>\n\n\n\n
  2. Signal at the storage location:<\/strong>As soon as the employee starts the order, the system sends a signal to the corresponding storage compartments. An indicator lights up on each compartment \u2013 usually a colored LED. <\/li>\n\n\n\n
  3. Removing items:<\/strong>Employees can see at a glance which items are needed and in what quantities. They pick up the product and remove the required number of items. <\/li>\n\n\n\n
  4. Confirmation of the pick:<\/strong>The pick is confirmed at the touch of a button directly on the compartment. Alternatively, touchscreens can be used. The system registers the step in real time. <\/li>\n\n\n\n
  5. Next pick or completion:<\/strong>Either the next compartment lights up or, in the case of a single pick, the order is completed. The system automatically reports back on the progress. <\/li>\n<\/ol>\n\n

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

    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 situation. <\/p>\n\n

    \"Pick-by-light
    Efficient picking thanks to visual signals directly at the storage location<\/figcaption><\/figure>\n\n

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

    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\n

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

      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\n

      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\n

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

      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\n

      Here are some typical areas of application:Automotive and supplier industry<\/strong><\/strong>Just-in-time logistics and absolute reliability are crucial in production. Pick by Light supports the supply of materials to assembly lines by displaying exactly which parts are needed and in what order. This virtually eliminates errors in parts provision. <\/p>\n\n

      Logistics<\/strong><\/strong>Many items, small quantities, and high availability requirements\u2014visually guided picking solutions simplify work in complex warehouse systems. Employees find the products they are looking for more quickly and avoid picking errors. <\/p>\n\n

      Pharmaceutical and medical technology<\/strong><\/strong>High standards of documentation and error prevention apply here. Digital systems with optical removal indicators enable precise tracking and ensure that the right product is supplied in the right quantity. At the same time, the material flow remains transparent and traceable. <\/p>\n\n

      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\n

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

      Tip<\/strong>: In this use case from ekko,<\/a> you can find out how a pick-by-light solution was implemented in practice, including an example from everyday warehouse operations.<\/p>\n\n

      Pick by Light and location technology: A sensible combination? <\/h2>\n\n

      Systems with visual picking support are particularly effective in stationary storage areas \u2013 but what happens when picking trolleys or entire rack units move around the room? This is where location technologies come into play. <\/p>\n\n

      Real-time localization systems (RTLS) such as Cavea Wirepas Mesh<\/a> or UWB can be used to track the position of mobile objects in the warehouse. This gives companies additional transparency regarding routes, locations, and process bottlenecks. <\/p>\n\n

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