Lighting the Way to Efficiency with Put-to-Light Order Picking
Put-To-Light Systems Boost Efficiency and Increase Labor Savings
Picture this: your business is booming. Orders are flying in, and the dollars are adding up. The problem? Manual picking is seriously slowing down your process. This is where put-to-light order picking comes in. By providing clear, visual instructions to warehouse staff, the system allows employees to batch pick multiple orders at a time and quickly separate them into a put wall for packing. How’s that for efficiency?
Whether you’re looking to enhance your current order fulfillment strategy or explore automation options, put-to-light technology can light the way forward.
So, How Does Put-To-Light Work?
Put-to-Light System in Put Wall
Often described as “pick-to-light in reverse,” put-to-light systems provide an automated method for breaking down larger quantities of items into individual customer orders, using lights to guide workers on where to place items. Also called “scan and sort,” this approach often involves batch-picking products and bringing them to a put station. Workers scan the items, and lights indicate where to “put” that customer order.
Put-to-light systems are ideal for operations handling a fixed number of orders with a wide range of SKUs. Using a put wall streamlines order sorting, allowing team members to manage multiple orders in a single pass. When items are scanned at the put wall, the appropriate slots automatically light up for each order requiring that item. Pickers can easily distribute products to the illuminated sections, turning off each light as they finish. Once that SKU is sorted, they move on to the next one.
The system also signals when an order is ready to ship. With lights on both sides of the put wall, one worker can sort items into orders on one side while another packs completed orders on the other. This setup dramatically improves efficiency and minimizes mistakes by eliminating the need to check labels or order sheets. Instead, pickers and packers simply follow the lights, ensuring a fast and accurate workflow.
This makes it a straightforward, efficient way to pick and pack orders in busy warehouses.
Experience the Benefits of a Put-To-Light System
Put-to-light systems offer a practical solution for streamlining order fulfillment, improving accuracy, and enhancing overall efficiency in warehouse operations.
Key Benefits of Put-to-Light Systems:
- Batch Picking and Sorting: Multiple orders are picked simultaneously, reducing travel time and increasing the overall speed of order completion.
- Reduced Human Error: Lights indicate where to put each item and how many go in each slot. Workers confirm the action, eliminating errors common to reading from an order sheet.
- Minimized Returns & Greater Customer Satisfaction: With less room for error, there’s less room for returns. Ensure your customers get what they want as fast as they can.
- Compact and Efficient Design: Put walls maximize efficiency in a small footprint, making them ideal for warehouses with limited space.
- Seasonal Flexibility: Rolling designs allow put walls to be easily adjusted or relocated to meet seasonal demands.
- Enhanced Productivity: Integrating a powered conveyor into the work area optimizes the speed and efficiency of sorting and fulfillment tasks.
- Customizable Solutions: Put walls can be tailored to fit your operation’s unique needs, streamlining sorting and order fulfillment processes.
All of these benefits lead to cost savings for you, too! By improving speed and accuracy, put-to-light systems reduce labor requirements, minimize errors, and cut down on costly returns. The result? Lower operational costs and increased profit margins.
Emerging Innovations in Put-to-Light Technology
As warehouse automation advances, put-to-light systems can integrate with exciting new technologies to deliver even greater efficiency and accuracy.
Take Autonomous Mobile Robots (AMRs) for instance. Advanced warehouse automation pairs put-to-light systems with AMRs to boost efficiency and accuracy. AMRs transport items from storage to put stations, reducing manual labor and costly travel time. Some robotic systems even assist in placing items into transport bins, streamlining sorting, and ensuring precise order fulfillment.
What about AI and IoT (Internet of Things)? The next generation of put-to-light systems can leverage IoT technology to track inventory in real-time. These systems would integrate with Warehouse Management Systems (WMS) to:
- Provide live stock updates
- Seamlessly communicate between picking, sorting, and shipping processes
- Optimize workflows with predictive analytics
- Increase overall system intelligence for smoother operations
Though it may not be standard use, you can also pair pick-to-light and put-to-light with voice-directed systems to further streamline your operation. There are multiple ways to combine emerging technology with these sturdy, proven systems.
Apex’s Data-Driven Approach to Put-to-Light Solutions
At Apex, we understand that no two warehouses are the same. That’s why our approach to any automation solution, including put-to-light integration, starts with a thorough data analysis of your operations. Depending on your application needs, Apex can help you combine pick-to-light and put-to-light systems to optimize your picking and packing operation.
Our team analyzes key metrics such as order frequency, product size and weight, and warehouse layout and flow to understand your operation’s unique needs. We then design a customized solution that maximizes efficiency and minimizes costs. Whether you’re processing e-commerce orders or large wholesale shipments, Apex’s tailored automation solutions ensure you meet your order fulfillment goals.
Contact Apex today to learn more about put-to-light technology and how it can help you achieve faster, more accurate order fulfillment.
