Overview
A Pick-to-Light (PTL) management system is a paperless order fulfillment technology that uses alphanumeric displays and LED lights to guide warehouse operators to the correct product locations during picking operations. It is widely used in warehouses, distribution centers, and manufacturing facilities to improve accuracy and efficiency.
How Pick-to-Light Works
- An order is received and processed by the WMS.
- WMS identifies the SKUs, quantities, and locations involved in the order.
- Lights at relevant SKU locations illuminate
- Lights at relevant SKU locations illuminate
- The picker walks to each lit location.
- Picks the indicated quantity of items.
- Confirms the pick by pressing a button on the light module.
- Confirmation is sent back to the WMS in real-time.
- Lights are turned off, and the system moves to the next pick.
Key Components used by Thanya in PTL systems
| Component | Description |
|---|---|
| LED Display Modules | Installed at pick locations; show quantity and light up to guide pickers |
| Push Buttons/Touch Sensors | Used by operators to confirm picks |
| Controllers | Manage power and data distribution to display modules |
| Warehouse Management System (WMS) | Central software that manages orders and synchronizes PTL activities |
| Pick Carts or Zones | PTL can be fixed (on shelving) or mobile (on picking carts) |
| Communication Interface | Wired or wireless connection between WMS and PTL hardware |
Types of Thanya’s PTL Systems
| Type | Description |
|---|---|
| Rack-Based PTL | Fixed light modules installed on shelving or bins |
| Cart-Based PTL | Mobile carts equipped with PTL modules for batch picking |
| Put-to-Light | Used during order sorting — lights guide where items should be placed for specific orders |
| Zone Picking PTL | Warehouse is divided into zones; workers pick within their zone using PTL guidance |
Benefits of Thanya’s PTL Systems
Operational Efficiency
- Significantly reduces pick time compared to paper or RF-based picking
- Streamlines high-volume or high-speed order fulfillment
Accuracy and Quality
- Reduces human errors due to visual guidance
- Increases order accuracy (often >99.9%)
Ease of Use
- Simple interface allows for quick onboarding and minimal training
- Multilingual support for diverse workforces
Real-Time Monitoring
- Supervisors can track picking progress in real time
- Provides insights into worker productivity and inventory levels
Flexibility
- Supports various order picking strategies (e.g., wave, batch, zone)
- Can be scaled or reconfigured as needed
Integration with Other Systems
- Warehouse Management Systems (WMS)
- Enterprise Resource Planning (ERP)
- Inventory Management Software
- Barcode/RFID systems (for verification and tracking)
- Automated conveyors or robotic systems (in advanced setups)
Common Applications
| Industry | Application |
|---|---|
| E-commerce Fulfillment | High-speed order picking |
| Retail Distribution | Store replenishment |
| Automotive | Component picking in assembly lines |
| Pharmaceutical | High-accuracy drug and medical device picking |
| Food & Beverage | Handling perishable goods with quick turnaround |
| 3PL (Third-Party Logistics) | High volume, multi-client order processing |