Pick to Light: An Innovation Optimizing Warehouse Operations

In the modern logistics world, speed and accuracy in the picking process are crucial factors for maintaining operational efficiency. As shipping volumes and order complexities increase, companies need systems that can accelerate the picking process while minimizing errors.

Pick to Light emerges as a visual-based technology solution that simplifies picking activities in warehouses. This system guides operators through indicator lights that illuminate on the racks where goods are located, displaying the number of items to be picked in real time. Without the need to read labels one by one or scan barcodes, the workflow becomes faster, more intuitive, and efficient.

What is Pick to Light?

Pick to Light is a warehouse picking system that uses indicator lights as visual guides for operators. This technology is designed to speed up the picking process by lighting up the location or storage slot where the goods are placed. Operators simply follow the illuminated lights to pick the items according to the quantity shown on the small display below the light.

This system eliminates the need for manually matching labels or scanning barcodes for every pick. As a result, the picking process becomes more intuitive, faster, and less error-prone. Pick to Light is commonly used in areas with high picking volumes such as e-commerce fulfillment centers, distribution warehouses, or light industry production lines.

This technology also supports multi-picking and batch-picking scenarios, enabling several orders to be processed simultaneously in one picking route. The combination of visual guidance and integration with a Warehouse Management System (WMS) makes Pick to Light a smart solution for enhancing warehouse efficiency and productivity.

Objectives and Benefits of the Pick to Light Feature

The Pick to Light system was developed to meet the industry's needs for speed, accuracy, and efficiency in warehouse picking processes. This technology provides a more intuitive, error-minimizing approach, making operators’ jobs easier without having to read documents or scan barcodes one by one.

1. Increasing Operational Efficiency

With visual guidance that directly indicates the location and quantity of items to pick, the time required for the picking process is significantly reduced. Operators can complete more orders in the same amount of time, thus increasing warehouse throughput.

2. Reduces Picking Errors

One of the biggest challenges in manual picking is human error. Pick to Light minimizes this risk with highly clear visual instructions. Each light unit only illuminates for items that need to be picked, reducing the chance of picking the wrong goods.

3. Easier Training for New Operators

Compared to conventional methods, the Pick to Light system is easier for new operators to understand. No deep knowledge of warehouse layout or inventory systems is needed—just follow the illuminated lights to perform the task.

4. Improves Customer Satisfaction

With higher accuracy and faster processing times, the risk of wrong shipments or delays is reduced. This directly impacts customer satisfaction, as orders are delivered on time and according to specifications.

How the Pick to Light Feature Works

Pick to Light works through a visual-based approach, integrating the warehouse management system (WMS) with LED indicator devices installed on every storage rack. This system transforms the conventional picking process into one that is much more efficient and intuitive, providing direct signals to operators about the location and quantity of items to be picked.

1. Integration with Warehouse Management System

Before picking begins, the WMS manages and translates order requests into digital instructions sent to the Pick to Light modules. Each instruction triggers the LED on the specific storage location to light up, also displaying the quantity to pick.

2. Visual Guidance During the Picking Process

Operators simply follow the illuminated lights, without needing to read documents or computer screens manually. Each lit rack indicates that items need to be picked from that location. After picking, operators can press a button on the module to confirm the process is complete.

3. Real-Time Feedback and Data Accuracy

Every confirmation is sent back to the system as real-time feedback. This ensures that every activity is automatically recorded, updating inventory data and providing managers with visibility into ongoing picking progress.

4. Efficiency for Multi-Order Processes

This system also supports batch picking, where one operator can pick items for multiple orders at once. The WMS organizes the optimal sequence and routes, while Pick to Light continues to provide visual guidance to ensure accurate picking for each order.

How Pick to Light Works with RFID-Based Systems

Pick to Light technology has rapidly evolved with the integration of RFID systems, creating even higher efficiency in modern warehouse operations. When these two technologies are combined, the picking process becomes more precise, real time, and less prone to human error—crucial in high-volume logistics environments

1. Combination of Visual Guidance and Automatic Identification

RFID enables the system to automatically recognize each item through embedded tags. When operators pick items indicated by Pick to Light, an RFID reader immediately verifies that the correct item is picked. This reduces the risk of picking errors and enhances system accuracy.

2. Real-Time Picking Validation

In addition to lights indicating item locations, RFID provides an extra layer of confirmation. When items are picked and passed through the reading area, the system instantly records the pick and automatically updates inventory in the backend. This removes the need for manual confirmation and accelerates the process.

3. Reduced Manual Intervention

One of the major benefits of combining Pick to Light and RFID is higher automation. Operators don’t need to manually match barcodes, which can be time-consuming and error-prone. The process is seamless—just read the RFID tag while following the light guidance.

4. Improved Productivity and Visibility

RFID integration also opens opportunities for more in-depth analysis of picking performance. The system can record picking times, errors, and efficiency for each operator. Warehouse management gains better visibility into daily workflows and potential areas for optimization.

Challenges in Implementing Pick to Light and How to Overcome Them

While the Pick to Light system delivers high efficiency in warehouse picking processes, like any technology, its implementation also presents several challenges that need to be considered before full adoption. Understanding these potential obstacles is important for developing a more mature and measured implementation strategy.

1. Initial Implementation Costs

One major challenge is the significant upfront investment. Pick to Light technology requires installation of physical devices such as light modules, sensors, and control systems integrated with the warehouse management system. For companies with limited budgets, this can be a serious consideration. The most realistic solution is to implement the system gradually, starting in high-intensity picking areas, while continuously evaluating its effectiveness and ROI.

2. System Integration Complexity

Pick to Light must be connected to backend systems like WMS or ERP to function optimally. However, not all company systems have an open architecture for direct integration. Therefore, companies need to ensure that their Pick to Light technology is supported by middleware or open APIs capable of bridging systems flexibly and reliably.

3. Team Adaptation

Implementing a new system usually requires an adaptation period, especially for human resources directly involved on-site. Without adequate training and guidance, operators may face confusion or even resistance to the new system. Simulation-based training and gradual familiarization are essential to ensure smooth and efficient technology adoption.

4. Coverage and Flexibility

Pick to Light is most effective for high-turnover SKUs in fixed locations. However, in warehouses with dynamic layouts or highly mobile items, the system becomes less efficient. In such scenarios, a hybrid approach—combining Pick to Light, RFID, and voice picking—will be more flexible to meet more complex needs.

Conclusion

Pick to Light is a modern solution addressing the challenges of efficiency and accuracy in the picking process across various industries. By leveraging an intuitive visual system, this technology increases picking speed, reduces errors, and drives overall operational productivity. Whether in logistics, e-commerce, manufacturing, or retail, Pick to Light offers high flexibility and easy integration with existing systems.

TUDI provides inventory solutions with Pick to Light features integrated with RFID technology and the DERAS Protocol-based Warehouse Management System, enabling precise and real-time picking. Want to know how this system can be applied in your warehouse or business operations? Visit our website for more information or to consult directly with our team.