Pick-to-Light Systems: Optimizing Logistics with Efficiency and Precision
03-Jun-2025 |
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In modern warehouses and industrial assembly centers, fast and accurate picking management is a key factor in productivity. Pick-to-Light (PTL) systems are one of the most advanced solutions for simplifying picking operations, reducing human errors and improving response times in order preparation.
What is a Pick-to-Light System A PTL system consists of a series of light indicators (typically RGB LEDs) positioned at each bin or storage location. When a order is generated, the devices light up to indicate to the operator which items to pick, in what quantity, and from which location. Some systems also include a small numeric display and buttons to confirm or correct the quantity picked.
Key Benefits
- Reduction of errors: Operators are guided visually, with a drastic reduction in human errors.
- Increased efficiency: Picking times are reduced thanks to an intuitive and immediate interface.
- Rapid training: Even inexperienced operators can be up and running quickly.
- Integration with management systems: The PTL can communicate in real time with the company ERP or WMS.
Innovative approaches: the hybrid Wi-Fi/Bluetooth system
In some cases, it is advantageous to adopt a mixed configuration that optimizes costs and energy consumption:
- A small number of main devices connected via Wi-Fi to the company network acts as a bridge.
- The secondary devices, which are more numerous and battery-powered, communicate with the main ones via Bluetooth BLE.
- Synchronization between devices occurs locally, with response times of less than 1 second.
Advanced examples of use
- Control of the bill of materials: The devices are switched on according to the bill of materials for the assembly of industrial products.
- Error management: By confirming or correcting the withdrawals, precise traceability is obtained.
- Centralized dashboards: The main devices display a summary of the order to facilitate the organization of the work.
Design considerations
When designing a system Customized Pick-to-Light requires
evaluating:
- Number of workstations to manage.
- Need for portability or fixing on shelves.
- Battery life (typically >6 months).
- Ergonomics for the operator (visibility, intuitive interaction).
- Software integration.
The Pick-to-Light system is a mature but constantly evolving technology. Integration with mesh communications, modular architectures, predictive algorithms and advanced dashboards makes it possible to create scalable, precise solutions that can be adapted to any industrial context. At TechCrafters, we custom design these systems, combining custom electronics, optimized firmware, and intelligent connectivity to take industrial picking to a new level of efficiency.
