L-mobile Pick-by-Light | Put Your Picking Processes in the Spotlight

Absolute process reliability with the Pick-by-Light method

Pick-by-Light describes the technology behind the paperless picking method. The Pick-by-Light system guides the picker to the respective storage compartments by means of an optical light signal and shows them the quantity that needs to be picked for a picking order. With the elimination of printed pick orders, the picking speed can be increased by using Pick-to-Light, and process reliability can be improved at the same time.

The picking process with Pick-by-Light technology uses an optical signal on the compartment displays. The display shows the picker the quantity that needs to be picked at the corresponding storage compartment. The removal for the picking order is then confirmed by pressing the acknowledgment button at the storage compartment. Following this principle, the Pick-to-Light system guides warehouse personnel through the entire picking order based on efficient routes. Instant real-time reporting of stock changes back to the ERP system enables you to monitor material flow at all times and from any location, and thus identify optimization potential.

Difference between Pick-by-Light and the Put-to-Light system

Paperless picking with compartment display works in two directions: The process where the item is picked by means of a light signal at the storage compartment describes the Pick-by-Light system. The term Pick-to-Light system is also often used when referring to Pick-by-Light. Both terms describe the same process and can be used synonymously.

On the other hand, when items or partial quantities are added to a storage compartment and restocking is performed by means of an optical light signal on the compartment display, this process is referred to as Put-to-Light. In contrast to the Pick-by-Light system, with the Put-to-Light method, the storage compartment where the picked item needs to be placed is highlighted by means of a light signal.

Pick-by-Light system
Picking items from a storage bin or point-of-use storage at an assembly work station
Light signal at the storage compartment shows the quantity that needs to be picked for a picking order
Paperless picking method
Confirmation of the withdrawal of material via the acknowledgment button at the storage compartment

Put-to-Light method
Partial quantities are transferred to a storage bin
Compartment display with light indicates which storage bin needs to be replenished with stock
Restocking in the warehouse or at an assembly work station
Confirmation of the withdrawal of material via the acknowledgment button at the storage compartment

Application areas for the Pick-to-Light system

The Pick-by-Light software from L-mobile can be used in practically all assembly or storage situations—whenever items need to be moved and regardless of whether the storage locations are stationary or mobile. If your employees need to have their hands free and high-speed picking with an absolutely minimal error rate is required, then it makes sense to use this technology. Complete Pick-to-Light solutions from L-mobile reliably assist users with the manual withdrawal of material during production and assembly. Not only does the use of paperless picking with compartment display significantly minimize manufacturing times at an assembly work station, but especially in the case of highly varied products right down to lot size 1, workers can also concentrate fully on the process, without first having to study job sheets, bills of materials, or assembly instructions. The Pick-by-Light technology uses a light signal to show production personnel when parts need to be picked from the point-of-use storage of an assembly work station. The withdrawal of material is confirmed by pressing the acknowledgment button at the storage compartment, and the error rate of incorrectly assembled individual parts is reduced to a minimum through the use of Pick-by-Light technology with the assembly system. As the Pick-by-Light system is connected directly to the ERP system, the withdrawal of material is posted automatically in real time.

Advantages of using the Pick-by-Light system at an assembly work station

Using the Pick-by-Light system in assembly supports digital worker guidance, especially when high-speed assembly with an absolutely minimal error rate is required.

No paperwork in the form of job sheets or bills of material

Employees’ hands are kept free

Reduced error rate during assembly

Digital worker guidance is supported

No confusion regarding the withdrawal of material

Constant stock control possible for c-parts

Short training period for employees

Direct feedback to the ERP system

Pick-by-Light process—how does picking with Pick-by-Light work?

Point-of-use storage with Pick-to-Light on the digital assembly instruction system – Error-free assembly processes

The Pick-by-Light modules are installed at all relevant storage compartments. They usually have at least one signal lamp and an acknowledgment button. A display shows the employee the location and quantity of items that need to be picked. After picking the items, the employee confirms the process, which initiates direct feedback to the ERP system. The real-time communication of information enables you to monitor material flow at all times and from any location, and thus identify optimization potential.

The Pick-to-Light system is one of the best paperless picking methods for logistics. When picking with Pick-by-Light, a light signal at the storage compartment shows warehouse personnel the quantity that needs to be picked for the pick order. In paperless picking with compartment displays, the L-mobile software guides pickers through the warehouse based on efficient routes, thus minimizing search times.

Like all paperless picking methods, the Pick-by-Light software uses a digital pick order, which is generated by the ERP system or warehouse management system that is used. The aim is to minimize process routes and picking errors, and to speed up order throughput times. What’s special about Pick-by-Light technology is that this form of paperless picking enables warehouse personnel to keep their hands free. With mobile picking, pickers use a barcode scanner or another mobile device to confirm the processing of their pick order. However, with Pick-by-Light picking, a light signal at the storage compartment shows warehouse personnel the exact location of the parts they need to pick for their order. In order for this to work, each storage bin must be equipped with a Pick-by-Light module (also referred to as a display or compartment display). When a new picking order is started, the compartment displays of the items that need to be picked are activated. I.e. the lights of the compartment displays switch on and the displays show the quantity of items required for the picking order.

L-mobile Digital Factory – Paperless production: Paperless picking with the Pick-to-Light method

L-mobile Digital factory – Automated replenishment management at the assembly work station with Pick-by-Light and E-Kanban

The light signal at the storage compartment enables pickers to quickly and clearly identify the correct compartment and process their pick order swiftly. A numeric or alphanumeric quantity display can be used to instruct warehouse personnel as to the number of items that need to be picked from the storage compartment. Warehouse personnel press the acknowledgment button on the compartment display following each withdrawal of material. The light and quantity display goes out and the stock change is seamlessly reported back to the inventory management system or warehouse management system in real time, where it is posted directly. In the event that a storage compartment does not contain enough parts for the picking order, the picker can correct and acknowledge the error within the order using the correction buttons on the quantity display. The new actual quantity is reported back (quantity corrections).

Why use Pick-by-Light software with storage bins?

Greater process reliability with Pick-by-Light systems: when compartment displays are used in picking, sensor lights ensure that as many sources of error as possible are eliminated and simple handling reduces picking times.

Lagersoftware mit Scanner - L-mobile warehouse für digitale Lagerverwaltung — Digital warehouse management

No paperwork for picking

Quick and easy operation

Search times are reduced

Incorrect picks are avoided

Short training period for employees

Quick and reliable order processing

Complete transparency and certainty over stock levels

Direct feedback to the ERP system

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L-mobile video screen

Wireless or wired: flexible use of Pick-by-Light technology

Pick-by-Light technology can either be used as a wired or wireless solution. Whichever Pick-to-Light system you opt for, the technology is always supplied with a signal lamp and an acknowledgment button at the relevant storage compartment. Whether you use a wired Pick-by-Light system or the wireless software when installing the hardware, the withdrawal of material is reported back to your ERP system in real time and you are always able to monitor material flow and identify optimization potential.

Wireless Pick-by-Light system

As a flexible and modern alternative to wired Pick-by-Light, L-mobile also offers a wireless solution. In this case, the wireless displays are connected to the corresponding access points over 868 MHz and thus form a stand-alone wireless system in your production. All signals from and to the displays can be transmitted without using any cables. This provides a very high degree of design freedom and allows the system to be adapted flexibly at any time.

The wireless displays have 3 color LEDs (red, yellow, and green) and a multi-line alphanumeric display that can be freely configured using the L-mobile Pick-by-Light software. The display also has an integrated acknowledgment button to confirm picking. Storage bins can be assigned to items via an L-mobile input interface. You are thus able to quickly and independently reorganize the storage bins at an assembly work station.

The small housing dimensions accommodate up to 10 wireless displays per meter and are therefore also suitable for compact feeding systems with a very small pitch. The driver software maps the location of every wireless display. You can then determine where each individual wireless display is at any given moment, making it possible to quickly adapt to new situations.

System security has also been taken into consideration: Integrated buttons on the back immediately detect any form of tampering and report this so that targeted incorrect postings in the ERP system can be prevented and identified straight away. Depending on the level of use, the battery life of the wireless modules is between 6 months and 3 years.

Wired Pick-by-Light system

In this version, the display modules of the Pick-to-Light software are connected via a BUS system and feature various display options. In addition to 6 different colored lamps, alphanumeric information can also be shown on the display. This display is freely configurable and can be flexibly assigned via the control of the L-mobile software. The display has an integrated acknowledgment button that employees can also use to confirm their activities. The Pick-by-Light system detects this signal, evaluates it, and initiates a withdrawal posting in the corresponding ERP system, for example.

L-mobile production simply integrated with your ERP

Our digital production software solution provides standard interfaces for all popular ERP systems.

Technical highlights of the Pick-by-Light system

Information is exchanged with the production and warehouse management system in real time

Secure data transfer and sabotage protection

Windows and LINUX operating system, can also be controlled using XML-RPC

Location mapping

Low battery load

Extensive wireless range of up to 100 m in an open space

User interface via web browser

Unlimited expandability

Individual configuration

Greater process reliability in assembly with the Pick-by-Light software

Ensure that your assembly personnel always have all the necessary parts at hand and always install them correctly during the assembly process. Pick-to-Light technology can be optimally combined with a digital assembly instruction system and automated replenishment with E-Kanban.

Software for digital assembly — Digital assembly instruction system

Guided assembly with the digital assembly instruction system

The L-mobile digital assembly instruction system guides your employees through the assembly process. When used in combination with Pick-by-Light at a work station, you can achieve a high degree of process reliability, even for manufacturing involving a wide range of variants.

Automated replenishment with E-Kanban

Ensure constant material supply in your manufacturing. Electronic Kanban sends requirement notifications instantly, with no manual effort required. When used in combination with Pick-by-Light, you can ensure the maximum efficiency of material flow.

L-mobile E-Kanban, E-Kanban with RFID — E-Kanban: automated replenishment with RFID

Digital production references

L-mobile case study: Digital warehouse management, warehouse ready for Infor COM, Mack Alu-Systeme GmbH

FoamPartner Germany GmbH - Recticel En

Fritz Stiefel Industrie-Vertretungen GmbH

Successfully navigate the path to becoming a smart factory through networked processes

Pick-by-Light and beyond: L-mobile is your strong partner and Industry 4.0 expert on the road to digitalization

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