Pick2Pallet: Integrated Pick-to-Light System for Pallet Jacks

Technology Overview

Pick2Pallet is an innovative pick-to-light system developed exclusively by The Raymond Corporation, designed to address the high costs and error potential associated with manual order picking, which can represent up to 55% of total warehousing expenses. This system uniquely integrates lighting technology directly into the material handling equipment itself—specifically, the forks of a Raymond pallet jack. It combines the auditory guidance of voice picking with a powerful visual confirmation system, creating a multi-sensory, error-proofed workflow for batch picking operations where an operator picks for multiple customer orders onto different pallets on the same truck.

How It Works

Core Principles

The core principle is the integration of visual "put-to-light" technology onto a mobile pallet jack, creating a dynamic guidance system that moves with the operator. It uses light beacons to eliminate guesswork in product placement, working in concert with voice instructions to create a closed-loop, verified picking process.

Key Features & Capabilities

The fork-integrated LED light system is the defining feature, bringing the guidance directly to the point of action—the pallet placement location—on a mobile platform. The system is engineered for seamless integration with voice picking, creating a powerful multimodal (audio + visual) interface that enhances both speed and accuracy. The rugged and reliable design is critical for warehouse environments; the LEDs are protected by the fork frame, and the IP65-rated electronics ensure durability and long-term performance with easy access for maintenance.

Advantages & Benefits

The primary benefit is a significant reduction in costly picking errors, specifically those arising from placing items on the wrong customer's pallet during batch picking. Raymond reports customer results of up to a 35% reduction in pick error rates. Concurrently, the system delivers a substantial productivity boost—up to 20% increase—by eliminating hesitation and search time, allowing operators to move confidently and quickly to the next task. This combination of higher accuracy and speed helps operations manage the challenges of a changing market more effectively, reducing labor costs per order and improving customer satisfaction.

Implementation Considerations

Implementing Pick2Pallet requires compatibility and integration with the facility's existing Warehouse Management System (WMS) and voice pick hardware/software. It is an option specific to Raymond pallet jack models, so it involves a procurement decision for new or retrofitted equipment. The system is optimized for batch picking workflows where an operator builds multiple palletized orders simultaneously; its value is maximized in these scenarios. The total cost includes the pallet jack with the Pick2Pallet option and the integration services.

Use Cases & Applications

Ideal For

This solution is ideal for wholesale, distribution, and manufacturing facilities that utilize pallet jacks for manual order picking, especially those engaged in batch or wave picking for multiple orders where product mixing is a major risk.

Performance Metrics

The provided content cites specific performance metrics from customer implementations:

• Productivity Increase: Up to 20% compared to pallet trucks without pick lights.
• Pick Error Reduction: Up to 35% reduction in pick error rates.

These gains directly address the high cost of order picking, aiming to reduce the 55% of warehousing costs it can represent.

Conclusion

Raymond's Pick2Pallet system is a clever and practical application of pick-to-light technology that moves the guidance system onto the vehicle itself. It effectively bridges the gap between manual processes and higher levels of automation by providing a simple, intuitive, and error-proofing visual cue exactly where it's needed most. For operations relying on manual pallet jack picking, especially in batch environments, implementing Pick2Pallet offers a straightforward path to immediate and measurable improvements in both accuracy and productivity, providing a strong return on investment and helping to "run better and manage smarter" in a demanding market.