Put to Light

Efficient Stock Replenishment

A put to light system is similar to a pick to light system, only instead of picking product to ship to consumers, it is designed to replenish stock to a store. Like pick to light, put to light systems are typically mounted on shelving or carton flow rack, with the individual open store shipping boxes placed above or below the designated put to light device. Common configurations have two shelves of 'put' locations within a put to light setup.


How Put-to-Light Works

In a put to light system, containers of items are directed to a put to light packing area where each store or order has an assigned packing location. The operator scans the container barcode on an inbound container (container entering the put to light area from receiving or storage), and put lights at the locations illuminate and display a quantity to put. The operator confirms the put by pressing the light or button after placing the quantity of the item needed into the shipping container. The operator repeats putting the same item to all locations with a light displayed. Put quantities can be any unit of measure that is less than a case, such as eaches or inner packs.

The Exacta put to light software tracks all item quantities put into each shipping container, with remaining puts to be completed from the original container as well as any remaining quantity in the original container.

Based on business rules and the put to light device used, operators might also have the ability to short a put to a container or split a put across multiple containers for the store or order. Other features within put to light include closing containers, indication of a full container to close, opening a new container and configurable scan verification as you open a container for the location.

If integrated with the Exacta warehouse control system routing module, containers of an item (inbound containers) can be dynamically routed to lanes based on workload (Each lane is configured for all stores - each lane identical). Based on how full a lane the inbound container can be routed to a different lane to help balance the work to keep all put operators busy.

Benefits of Put-to-Light

  • Same hardware devices and software technology as used for pick to light.
  • Option to use a single put to light device for two locations (up and down) common in retail distribution layouts.
  • If a SKU tends to get distributed to most of the stores, this method of distribution results in a high put density (lots of put opportunities with very little walking), and an efficient transfer of product.
  • Put to light can also be used on the put side of flow rack in order consolidation areas.

Interested in Put-to-Light technology or just want to know more about it?