Pick-to-Light Systems: Accuracy and Efficiency for Manufacturing

Technology Overview

Pick-to-Light systems from Banner Engineering are light-directed solutions designed to enhance manual processes in industrial automation, manufacturing, and order fulfillment. They address the inherent challenges of manual picking and assembly, which are often prone to being slow and error-prone. By providing clear, intuitive visual cues and instant verification feedback, these systems transform complex search-and-pick tasks into simple, guided actions. This technology is versatile, supporting applications from discrete part picking on assembly lines to large-scale e-commerce fulfillment, with the overarching goal of improving quality, speed, and cost-efficiency.

How It Works

Core Principles

The core principle is visual guidance with closed-loop verification. The system uses light to direct the worker to the exact location and uses integrated sensors or buttons to confirm the action, creating an error-proofing loop that prevents mistakes from moving downstream.

Key Features & Capabilities

The visual guidance with verification is the foundational feature, combining clear indication with a mistake-proofing step. The availability of wireless pick-to-light options provides significant flexibility, allowing systems to be deployed on mobile carts or in areas without fixed wiring, enabling agile responses to "calls-for-parts." The dual functionality as pick-to-light and put-to-light with the same hardware maximizes the utility of the investment. Advanced features like programmable secondary buttons add operational intelligence, such as allowing workers to signal low inventory directly from the station, preventing stock-outs.

Advantages & Benefits

The primary benefit is a significant reduction in human error, which directly translates to higher product quality, fewer defects, and less rework. This leads to substantial cost savings in waste and correction. The system dramatically increases picking speed and efficiency by eliminating time spent searching and reading instructions, allowing workers to "pick faster and more accurately." This efficiency gain improves throughput and can reduce labor costs per unit. Furthermore, it enhances customer satisfaction and brand reputation in fulfillment applications by ensuring order accuracy and faster shipment times.

Implementation Considerations

Implementation requires an analysis of the specific application—whether it's assembly, kitting, or order fulfillment—to design an optimal workflow. The choice between wired and wireless solutions must consider factors like facility layout, need for mobility, and installation constraints. Integration with existing production or warehouse management software is necessary for task assignment and data exchange. While scalable, the system design must match the deployment scale, from a single kitting station to a vast network of pick faces across a distribution center.

Use Cases & Applications

Ideal For

This technology is ideal for any manufacturing or logistics environment where manual picking, assembly, or restocking is a critical and error-sensitive part of the process.

Conclusion

Pick-to-Light systems from Banner Engineering offer a proven, cost-effective method to bridge the gap between fully manual and highly automated processes. By providing simple, error-proof guidance, they deliver immediate improvements in accuracy, speed, and operational cost. For companies in manufacturing and distribution looking to boost quality, satisfy customers, and improve their bottom line without a massive capital investment in robotics, implementing a tailored Pick-to-Light solution is a strategic and highly effective step toward smarter, more efficient operations.