Before a product can be assembled, all its individual parts and components must be collected from storage. This picking process, often referred to as “pick-to-light,” is a critical step in manufacturing and logistics. During this stage, operators select the correct parts from the designated bins—often spread across multiple locations—and prepare them for assembly.
In addition to picking, the process of kitting components, also known as “put-to-light,” involves grouping and packaging individual parts required for a specific assembly, production task, or order into a single, organized kit.
Pick-to-light. Put-to-light.
Pick-to-light sensors use LED indicators mounted above each bin to visually guide operators during the picking process. When a part is required, the corresponding light illuminates, often also showing the quantity to pick. Different types of sensors are available, including captive touch buttons, mechanical push buttons, and proximity sensors that detect when a hand enters the bin.
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This solution combines a 3D sensor with a projector system to indicate the correct picking location. Instead of installing hardware above each bin, a projector mounted above the workstation highlights the correct bin with light patters or colors. Some advanced systems even warn operators (e.g. blink red) when they reach into the wrong bin
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A more straightforward approach uses barcode scanners to confirm that the correct parts are picked. Each bin or part is labelled with a barcode, which the operator scans during picking. This can be integrated with a counting system to track quantities and ensure completeness. Either you can use a dedicated barcode scanner or use our app.
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A RTLS (Real-Time-Location System) bracelet enables complete flexible picking. Once bin and locations are mapped into the operator guidance system, the bracelet identifies the operator’s position and confirms whether the correct bin is accessed. This approach eliminates the need for physical hardware or scanning at each station.
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