Faced with increasing customer demands and the growing complexity of e-commerce operations, optimizing order preparation is becoming a strategic lever. Among the most effective technologies, pick to light stands out for its speed, ease of use and ability to reduce errors. Let’s find out how this light solution can transform your warehouse.
In an e-commerce warehouse, every second counts. As order volumes increase and delivery times shorten, traditional picking methods are reaching their limits. Picking errors, lack of traceability, slowness… these are all friction points that weigh on warehouse productivity and customer satisfaction.
This is where the pick-to-light solution comes into its own. Thanks to an illuminated guidance system, it enables operators to increase efficiency while simplifying their daily tasks. Combined with a modern WMS/OMS, it integrates perfectly with fluid, connected omnichannel logistics.
- Definition of pick to light
- Pick to light vs. put to light: what are the differences and when should you choose?
- Concrete benefits for an e-commerce warehouse
- Integrate pick to light into your WMS/OMS/TMS stack
- Alternatives and complements (voice, RF, goods-to-person)
- Estimating ROI: a quick method
- 30-day deployment plan (pilot)
- DNVB express case study (model)
- FAQ – Pick to light
In this article, we’ll look at how pick-to-light works, how it differs from put-to-light, its concrete benefits for e-commerce SMEs, and the steps you need to take to rapidly integrate it into your warehouse via a pilot deployment plan. A complete guide to rethinking your order picking with method and results.
Definition of pick to light
Pick to light is a light-assisted order-picking system. This process enables operators to quickly locate the products to be picked in a warehouse. It relies on LED displays positioned on the shelves, which light up to indicate the correct picking location.
Unlike traditional methods, this system reduces human error while improving execution speed. It is in line with a logic of “workstation ergonomics” and industrialization of picking, highly sought-after in e-commerce environments subject to strong seasonality.
How a light guidance system works
A pick-to-light system is based on a series of components: light modules, validation buttons, infrared sensors and control units. When a command is received, the modules light up to guide the operator to the right location.
Each slot is equipped with an LED display indicating the quantity to be picked. Once the item has been entered, the operator validates the action by pressing a button. Some advanced systems use sensors to automatically detect gripping.
The process is fluid, fast, and adapted to intense flows, particularly in batch picking or wave picking activities.
Link with WMS/OMS: real-time data exchange
Pick to light becomes truly effective when connected to a WMS/OMS. The WMS transmits order-picking data to the light system in real time. TheOMS orchestrates the distribution of orders to the various warehouses.
At Shippingbo, integration is based on powerful warehouse APIs and marketplaces connectors that enable seamless order orchestration. The result? Real-time traceability and faster shipping.
Pick to light vs. put to light: what are the differences and when should you choose?
Pick to light is used to pick products into one container. Conversely, put-to-light is used to dispatch picked products to several individual orders.
Pick to light is ideal for high-speed environments, while put to light is preferred for managing returns or breaking up multi-reference orders.
Typical e-commerce cases: order splitting, kitting, returns
In e-commerce, these technologies come into their own:
- Order bursting in the sorting area
- Kitting personalized or packaged products
- Management of high-season returns
The choice between pick and put depends on the logistics process and the type of flow to be handled.
Concrete benefits for an e-commerce warehouse
The adoption of pick to light reduces picking errors by up to 60% and improves warehouse productivity by 30-50%. Operators gain in speed and comfort.
Improvedworkstation ergonomics reduce physical fatigue. UPH (units/hour) indicators are more easily monitored, and gains are observed in terms of complete cycle time.
Customer impact: SLA, D+1, satisfaction
For end-customers, these improvements mean better SLAs (Service Level Agreements), achievable D+1 shipments, and fewer delivery errors.
A seamless customer experience promotes loyaltyreduces the number of after-sales contacts, and enables us to differentiate ourselves even on demanding channels such as click & collect or marketplaces.
Integrate pick to light into your WMS/OMS/TMS stack
Successful integration of pick-to-light requires appropriate WMS connectors, API interoperability and control from a unified interface.
The Shippingbo solution offers a unified OMS/WMS/TMS suite for seamless order orchestration, whatever the sales channel or 3PL provider.
Data to be mapped: SKUs, locations, quantities, status
To guarantee optimum integration between a pick-to-light system and a WMS/OMS, it is essential to precisely define the data exchanged. This mapping forms the basis of communication between the systems, and conditions the reliability of operations.
- Product SKUs: each reference must be unique and standardized to avoid any ambiguity during picking. The lighting system is only triggered if the SKU corresponds exactly to the one expected by the WMS.
- Storage locations: the logistical address of each item (shelf, rack, bin) must be precisely recorded. The light module activates directly on the identifiedphysical location, reducing search errors.
- Available quantities: real-time information is crucial. The WMS synchronizes stock levels to light up the right LED displays and indicate the exact number of units to be picked.
- Order status: preparation in progress, validated, dispatched, etc. This data is used to automatically update tracking and ensure traceability in real time.
The right WMS settings automate light guidance according to stock data, while guaranteeing seamless preparation between systems.
Alternatives and complements (voice, RF, goods-to-person)
Pick to light is not the only technology available to optimize order picking. Depending on the type of flow, the volume of activity or the configuration of the warehouse, other solutions can be considered, alone or in combination.
- Voice picking: using headphones, the operator receives voice instructions to guide his movements and picks. This method is particularly suited to noisy environments, or when hands need to be kept free. It is particularly effective in the food and fast-moving goods sectors.
- RF terminals: based on portable terminals linked to the WMS by radio frequency, they offer great flexibility of use. Slower than pick-to-light systems, they are ideal for warehouses with a large product catalog, but a lower throughput rate.
- Goods-to-person: here, the products are moved to the operator by conveyors or robots. This is a high-performance solution, ideal for large volumes, but one that involves high installation costs and a high level of automation.
When pick to light is not optimal
Pick to light is less relevant in certain contexts. For example, in warehouses with a very low stock rotation, light modules are likely to remain under-utilized. It can also show its limitations when locations change frequently, as updating the system becomes complex. Last but not least, it is less suited to mass storage or outdoor areas, where the installation ofpick-to-light shelving or dynamic racking is difficult to justify.
Before deploying a project, a detailed flow audit is essential. It enables us to verify the relevance of the technology to actual needs, and to assess whether a hybrid approach, such as a combination of pick-to-light and voice picking, would deliver greater value.
Estimating ROI: a quick method
The return on investment of a pick-to-light project can be measured by comparing productivity gains, reduced errors, fewer after-sales disputes and avoided labor costs.
On the cost side, consider the cost of installation, hardware (modules, screens), licenses and operator training.
30-day deployment plan (pilot)
A pick-to-light project can be launched rapidly via a pilot deployment plan. Here are the key steps:
- Flow audit and bottleneck analysis
- Application of the ABC slotting
- Creation of a test area (a few shelves)
- Operator training and start-up
- Gradual ramp-up to full roll-out
This approach makes for a smooth, reversible implementation.
DNVB express case study (model)
A DNVB specializing in tech accessories has adopted pick to light with Shippingbo. Before: 18% picking errors, 120 UPH. After: 2% errors, 190 UPH.
Gains observed in 6 weeks :
- +58% warehouse productivity
- 78% fewer after-sales service requests
- ROI achieved in less than 5 months
Pick to light offers a real answer to the logistics performance challenges faced by e-tailers: fewer errors, greater speed, better tracking of operations, and satisfied customers.
Combined with a modern WMS/OMS like Shippingbo’s, it integrates naturally into your omnichannel strategy to improve your flows, your performance indicators and your logistics ROI.
Request a Shippingbo demo to see how you can orchestrate your omnichannel orders and prepare faster :
FAQ – Pick to light
Yes, if it’s connected via APIs or connectors. Information flows in real time between systems.
Yes, Shippingbo can interface with the pick-to-light mechanism without data disruption.
Pick to light is used to guide the picking of products. Put to light is used to guide the distribution of products into target packages or zones.
Yes, it can be used with voice picking, RF terminals or other systems as required.
The result is higher productivity, fewer preparation errors and greater stock reliability.
Yes, the system can display multiple locations at the same time to manage multiple orders.
It is very suitable for small parts that turn quickly, but less useful for heavy or bulky products.
All you have to do is create a test area with the most popular products, train the teams, then expand according to the results.