Pick-to-Light in Smart Warehouses: A Solution for Enhancing Operational Efficiency and Accuracy

1. The Development Context of Pick-to-Light Technology in Modern Logistics

Over the past decade, the global logistics and warehouse management sector has undergone profound changes driven by e-commerce growth, lean manufacturing, and digital transformation. Traditional warehouse models, which rely heavily on manual labor and individual experience, have increasingly revealed significant limitations, including slow processing speed, high error rates, and rising operating costs.

According to numerous supply chain studies, order picking accounts for approximately 50–70% of total warehouse operating costs. It is also the stage where errors occur most frequently, directly affecting delivery time, return costs, and overall customer experience. Under growing competitive pressure, enterprises are therefore compelled to seek technological solutions that optimize picking processes while keeping investment costs under control.

In this context, Pick-to-Light has emerged as an effective intermediate solution, positioned between traditional manual picking methods and fully automated systems such as robots or AS/RS. This technology enables enterprises to significantly improve picking efficiency while maintaining flexibility in warehouse operations.

2. What Is Pick-to-Light?

Pick-to-Light is an order picking support system that uses LED indicator lights, quantity display modules, and confirmation buttons, installed directly at storage locations such as racks or bins. When a picking command is issued from a Warehouse Management System (WMS) or ERP, the light at the required storage location is activated, guiding workers through a highly visual and intuitive process.

Unlike paper-based picking or handheld scanner–based methods, Pick-to-Light minimizes the need for reading and interpreting information. Workers simply follow light signals and displayed quantities. As a result, this technology is particularly well suited for warehouses with a large number of SKUs, small-order quantities, and high picking frequency.

3. Operating Principles of a Pick-to-Light System

1️⃣ Order / Model Initialization

2️⃣ Printing and Scanning the Order Label

3️⃣ Control PC Processing and Command Dispatch

4️⃣ Controller and Junction Box Signal Distribution

5️⃣ Pick-to-Light Indicators Activate at Correct Locations

6️⃣ Confirmation via Barcode Scanner or Push Button

7️⃣ Mapping and Error Prevention Mechanism

8️⃣ Picking Completion and Transfer to Assembly

4. The Role of Pick-to-Light in Smart Warehouses

Within the smart warehouse model, Pick-to-Light is not merely a picking aid but a component of a broader automation ecosystem. When integrated with management systems and other technologies, Pick-to-Light contributes to a seamless data flow from order placement to final delivery.

Notably, Pick-to-Light is often considered an ideal transitional step for enterprises that are not yet ready to invest in robotics or fully automated systems but still seek improved efficiency and accuracy in warehouse operations.

5. Key Benefits of Pick-to-Light Technology

Increased Picking Speed

Pick-to-Light significantly enhances labor productivity. Practical reports indicate picking speed improvements of 20–50%, or even higher in warehouses with optimized layouts.

Reduced Error Rates

By providing clear visual guidance, Pick-to-Light minimizes errors related to location, quantity, and item identification—particularly critical in industries such as pharmaceuticals, electronics, and medical supplies.

Easy Training and Deployment

The system requires minimal technical expertise, allowing new or temporary workers to become productive quickly, thereby reducing training costs and improving workforce flexibility.

Improved Working Conditions

Lower cognitive load and simplified repetitive tasks contribute to better working conditions, higher productivity, and improved employee retention.

6. Comparison with Other Picking Methods

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Compared to Pick-by-Voice or robotic picking, Pick-to-Light requires lower initial investment while delivering substantial efficiency gains.

7. Practical Applications of Pick-to-Light

Pick-to-Light is widely applied in:

• Electronics manufacturing – accurate component picking based on BOM

• Pharmaceutical and medical warehouses – lot and code accuracy

• Apparel and footwear – sorting by size, color, and SKU

• E-commerce operations – high-frequency small orders

• Fulfillment centers – reduced order processing time

8. Integration Trends with Emerging Technologies

In the context of digital transformation, Pick-to-Light is increasingly integrated with:

• Advanced WMS for real-time inventory management

• RFID for item and lot verification

• IoT for equipment and operational monitoring

• MES/SCADA in industrial production environments

This integration elevates Pick-to-Light from a picking aid to a core element of comprehensive warehouse automation systems.

9. Limitations and Deployment Challenges

Despite its advantages, Pick-to-Light presents certain limitations:

• Initial investment in equipment and infrastructure

• Requirement for relatively stable warehouse layouts

• Limited suitability for bulky or oversized items

Enterprises should therefore carefully assess warehouse characteristics, SKU volume, and order frequency before implementation.

10. Development Prospects of Pick-to-Light in Vietnam

As Vietnam accelerates digital transformation, smart logistics, and lean manufacturing, Pick-to-Light is increasingly viewed as a practical solution for medium and large enterprises. Compared to robotic systems, it offers improved operational efficiency without excessive financial burden.

Experts widely believe that Pick-to-Light will continue to play a vital role in modernizing warehouse operations in Vietnam, particularly as enterprises gradually transition toward smart and fully automated warehouses.

11. The Role of Beetech in Deploying Pick-to-Light Solutions in Vietnam

Beetech’s Pick-to-Light Solution Strategy

Beetech delivers not only Pick-to-Light hardware but comprehensive solutions, including:

• Zone / rack / line–based Pick-to-Light architecture design

• Integration with WMS, MES, and ERP systems

• Combined Barcode – RFID – Pick-to-Light error control

• Application of Poka-Yoke mechanisms in production

This approach suits factories and logistics centers with stringent requirements for accuracy, traceability, and process control.

 

Pick-to-Light + RFID in Beetech’s Model

A distinguishing feature of Beetech’s systems is the integration of RFID at the verification layer, beyond visual guidance alone:

• Pick-to-Light provides location and quantity guidance

• Barcode/RFID verifies correct component and lot

• Data is synchronized with WMS/MES in real time

This model:

• Reduces the risk of correct-location but wrong-item picking

• Supports model-based and BOM-driven production

• Enables expansion to assembly lines, kitting, and line feeding

Practical Value in the Vietnamese Context

Under Vietnam’s manufacturing and logistics conditions, Beetech’s Pick-to-Light model offers:

• Compatibility with existing warehouse layouts

• Lower investment compared to robotic picking

• Ease of workforce training

• A gradual pathway toward smart factories and warehouses

Thus, Pick-to-Light serves not only as a short-term solution but as a technological stepping stone toward long-term automation.

12. Conclusion

Pick-to-Light is not merely a picking support technology but a strategic solution that enables enterprises to balance cost, speed, and accuracy. In an increasingly competitive environment, adopting Pick-to-Light represents a practical and effective approach to enhancing operational capability and strengthening competitiveness within modern supply chains.

📧 Email: info@beetech.com.vn
🌐 Website: https://beetech.com.vn