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Pick-to-Light System

Pick-to-light system is the semi-automated picking system aided with digital displays so as to achieve fast and efficient picking operation.

Pick-to tote movement on conveyors is linked to the display units. When a pick-to tote arrives in a picking zone, the display units within the zone shows picking quantity. The operator responsible for the zone picks the requested quantity from picking window, pushing completion buttons next to the display units.

Pick-to-Light System works great for a wide variety of picking needs, for both LMHV (low-mix, high-volume) and HMLV (high-mix, low-volume) operations.

Variations & Add-ons

Multi order application "eye-navi"

Daifuku's original pick-to-light application "eye-navi" is a advanced pick-to-light application using RFIDs for pick-to tote identification.

In "eye-navi" application, a pick-to tote, an RFID tag, and a display unit travel together on conveyor lines. The movement of pick-to-light indicators on inventory racks and that of totes on conveyors are synchronized so as to indicate both "How many items to pick from which picking locations" and "Which is the right pick-to tote to throw in the picked items" to operators.

"eye-navi" application provides following benefits comparing to basic pick-to-light system.

  • Higher productivity : Since the movement of a pick-to tote on conveyors is individually controlled by RFID, the space between pick-to totes is almost zero. This makes it possible to minimize the waiting time between orders and avoid slowing down of entire system due to picking delay at one picking zone.
  • Higher accuracy : A wireless display unit shows the right tote for placing picked items. Furthermore, the inspection function provided makes it possible to double-check the tote contents in real time.

Multi order application "Automatic drop-in table"

In this application, automatic drop-in tables equipped with indicators and weight scales are set above the pick-to tote conveying line. The movement of pick-to-light indicators on inventory racks and that of table indicators are synchronized so as to indicate both "How many items to pick from which picking locations" and "Which is the right table to place the picked items" to operators. Furthermore, the weight scale checks the total weight of picked items for verification prior to dropping into totes.

This application provides following benefits comparing to basic pick-to-light system.

  • Higher productivity : This application allows a picking operator to work on multiple orders simultaneously before pick-to tote arrival. It consequently levels variation of busyness in different picking zones and increases the total system productivity.
  • Higher accuracy : A display unit provided on each table guides the operator to the right position to eliminating miss-entry risk. The weight check function additionally inspects picking accuracy.

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