Pick To Light (PTL) Technology

How Pick To Light (PTL) Technology Works

In a Pick To Light system, the order number or barcode associated to the order number on a shipping carton or tote is scanned, then lights illuminate, indicating locations where items need to be picked. Each pick light displays a quantity of the item to be picked. The Pick To Light solution can be configured to display to the operator whether they need to be picking pieces or cases along with the quantity. Depending on business rules, operators may also have the ability to indicate short picks through the pick to light devices. Using this type of light directed picking, operators are able to keep their hands free, do not need to wear or carry any devices and can quickly identify the next pick required. Once the operator reports a pick completion within the Pick To Light System by pressing a switch the warehouse management system or host system is updated in real-time.

Common Pick To Light (PTL) Devices

• Standard PTL
  • Red, blue, green colors available
  • A big full-lighting switch which can be checked from near or afar
  • By setting lighting mode, the light can blink upward or downward to correctly indicate its location
• No Digit PTL
  • Used at a location that does not need quantity display
  • Can be used as completion switch after picking or sorting of one order is finished
• Five Digit PTL
  • Can display case pick quantity and broken case quantity at the same time. It can also display location number and pick quantity at the same time
• Three Digit PTL
  • Can display case pick quantity and broken case quantity at the same time. It can also display location number and pick quantity at the same time
• PTL with Quality Adjustment Keys
  • Operator can change pick or sort quantity to match the physical quantity
  • The changed quantity can be sent back to the host computer by pressing the designated switch
• PTL with Ten Letter Alphanumeric Display
  • 10-Digit alphanumeric display
  • Compact and inexpensive, suitable at each bay or zone, providing easy reference to operators
• Two-Two PTL
  • This device can display case pick quantities and broken case pick quantities
• Triple Color PTL
  • One device can display three different colors; red, green and blue
  • High intensity full-lighting
  • Applicable for color-coded work operations

Pick To Light (PTL) Benefits Include:

• Paperless, Hands-free, User-friendly Operation - Pickers no longer need to carry around paper pick lists that can so easily be lost or misplaced. Both hands are free to use for picking. Pickers simply look for pick lights that are lit up
• Simple to learn and use - Minimal training time is required. Operators prefer using pick to light over paper pick lists based on ease of use (looking for a light and reading the number compared to reading a location, item and quantity from paper) and speed with which pickers can complete the work
• Improved Accuracy - Improvements to (over 99%) compared to paper based picking, reducing errors in picking and increasing order accuracy. Better order accuracy leads to increased customer satisfaction
• Increased Productivity - Increase efficiency and picking rates (up to 450 lines per person hour). Individual operator productivity can be increased up to 4 or 5 times over traditional, paper-based picking solutions as Pick to Light Technology reduces product location search times
• Reduced Operating Expenses - Fewer labor hours required to pick the same order volume
• Easy to Install - Easily mounts to virtually any type of shelving or rack. Cableless pick to light device installation dramatically reduces install times and complexity. Works for a wide range of locations, whether its 50, 500 or 5,000 lights in the system
• Robust Reporting -Personnel productivity reports help you engage your works and judge them against their peers

Exacta® Acculight™ Pick to Light Installation Benefits

• Pick To Light devices can be easily installed on existing equipment such as racks and picking carts.
• Pick To Light devices use cableless duct for an easy snap-in installation which requires no confusing cables. This technology results in significantly reduced installation time.
• Pick To Light devices can be easily reconfigured when resizing or repositioning locations.

Applications that maximize the benefits of Pick To Light (PTL)

• High Velocity Carton Flow
• Carousel Light Towers
• Put Bars for Totes
• Full Case Picking from Static Rack
• Shelving
• Pick to Light cart

Pick To Light (PTL) Features

• Easy to read - Bright Indicator Lights
• Easy to learn - Within 15 minutes, most operators are off and running
• Easy to configure - For adding additional Pick to Light devices, run complete diagnostics, etc.
• Can work in conjunction with RF hand-held units
• Durable devices to handle industrial use and varying environments
• Real-time communication with host computer
• Cableless duct for minimum installation time
• Pick To Light devices are made with unsurpassed quality and are priced competitively.
• Pick To Light modules can be configured for sub-zoning to take advantage of surges in picking demand by adding additional picking operators.
• Configuration also allows batch picking or single order picks.
• Pick To Light modules can serve as a stand alone area of automation, be an integral module with Exacta®, or interface directly to other Warehouse Management System (WMS) or ERP systems.
• Bus bar technology allows infinite horizontal adjustment of the physical Pick to Light device.

Industries Where Pick To Light (PTL) is Used

Distribution, Manufacturing, and Assembly operations in any industry can benefit from PTL technology.

Budgetary Pick To Light (PTL) Pricing

For typical picking operations (standard carton flow rack with approximately 1,000 SKU locations), an Acculight "Pick to Light" system costs between US$100 and $115 per display location. These prices include:

• Work indicator devices (directs the activities of the operator in a zone or sub zone)
• Pick devices (provides SKU specific information at each pick interface)
• Bus rail (delivers power and communications to individual devices)
• Bus rail accessories (e.g. power-to-rail connectors, signal terminators, rail covers)
• Power supplies (transform and rectify 120 VAC)
• Ethernet link boxes and mechanical installation

Pick to Display and Pick to Light devices can both be used in the same system based on the picking characteristics of the specific products. One light can be used to direct pick to multiple pick or put locations for additional cost reduction.

The prices listed above do not include the PTL software, ERP/WMS integration software, computer hardware, and project management. Please contact us for a more detailed quote based on your specific requirements.