Daifuku's pick-to-light digital pick system queues workers to pick items in accordance with the digital indicator on a rack or shelf. It can integrate with standard shelving, an automated storage & retrieval system (AS/RS), conveyor, overhead monorail and sorting transfer vehicle (STV) and is effective for case and piece picking.
How it works
Input:
Product is assigned to the locations on the flow rack by the warehouse management system.
The warehouse management system or warehouse control system tracks the inventory quantities and generates replenishment orders to move product to the locations once the predetermined replenishment value is reach.
Output:
As orders are released for picking, location lights flash to identify the pick location and the quantity to pick is displayed.
Workers pick the requested quantity then press the button to confirm the pick.
The confirmation of the pick is electronically sent to the host once the Worker presses the light to confirm the pick. No other action is required to update the warehouse management system.
Primary Problems Addressed:
Productivity
Orders are becoming smaller and more frequent
Pick cycle times are too long
Errors
Excessive picking errors
Extensive counting errors
Inventory
Frequent out of stock problems
Extensive overstock
Frequent lost stock
No real-time material control
Poor product accessibility
Lack of FIFO control
Ergonomics
Workers walking long distances
Features
Lights indicate item quantity and pick location
Paperless system
Open system architecture works with most WMS software
Carrier-on-wire system with snap-on, snap-off answer kits
Links to host computer for real-time tracking of order status and inventory levels
Benefits
Increases productivity - paperless, priority-based picking can double productivity while slashing errors
Enhances efficiency - eliminates wasted time searching for products
Decreases errors - workers can accurately pick fast-moving, high-frequency items in seconds
Improves inventory control - Easy to program and modify system as needed
