What is Pick to Light in a Warehouse?
Imagine grabbing items in seconds, rather than wasting minutes hunting through shelves and scribbling on clipboards.
That daily chaos in warehouses? Pick to Light helps fix it by replacing guesswork with glowing, guided precision.
This tech-driven system uses LED indicators to show precisely where and what to pick – no paper, no stress. Still, setting it up can be tricky, especially balancing speed with accuracy during busy shifts.
For contractors installing warehouse power or business owners upgrading systems, we design safe, code-compliant setups for Pick to Light.
Our Left Coast Electric makes complex installations easy, keeping operations fast, safe, and efficient.
Understanding Pick to Light in Warehousing
Definition and Purpose
Pick to Light is a warehouse order-picking technology that replaces paper checklists and manual searching with visual guidance. Using LED light displays and digital indicators mounted on shelving or racks, it directs workers to the exact location of each product needed for an order.
Everything changes when your team no longer relies on paper checklists or manual guesswork. Pick-to-light systems use visual signals – like LED lights – to guide staff straight to the right product on the shelf.
It fits into the order fulfillment process by making item picking faster and more accurate. Designed for warehousing, it allows workers to select multiple orders quickly, helping reduce delays and mistakes.
Pick to Light systems speed up orders where every second matters, especially for businesses managing high product volume.
How Pick to Light Systems Work
When an order comes in, the system lights up the correct storage locations and often displays the quantity to pick. Workers simply follow the lights, select the item, and confirm it with the push of a button or scanner.
This technology dramatically improves speed and accuracy in order fulfillment, making it ideal for warehouses handling high order volumes or complex inventory. It reduces human error, cuts down on training time for new staff, and integrates easily with warehouse management systems.
In short, Pick to Light streamlines the entire picking process, ensuring faster orders, fewer mistakes, and better efficiency where every second and every product counts.
Benefits and Use Cases of Pick to Light
Operational Advantages
The beauty of this system lies in simplicity – lights eliminate second-guessing. Steps are reduced, so workers walk less and work faster.
It tracks inventory instantly, removing the need for after-shift stock audits. Mistakes drop sharply since errors are caught before they leave the shelf.
This accuracy is particularly helpful during rushes, where minimizing mix-ups becomes a business lifesaver.
Training and Labor Optimization
Training new team members becomes a breeze. Visual cues mean seasonal workers can be productive within hours, not days.
Long-term staff feel less strained, which boosts morale and adds energy to their routine. Less time training means more hands actively picking.
Our clients have seen lower labor costs simply by equipping workers with intuitive light-based guidance.
When Pick to Light is Most Effective
If your facility handles thousands of orders daily or faces high seasonal pressure, this system fits perfectly.
It’s beneficial in places with fast onboarding needs or lots of employee turnover.
We’ve helped businesses scale their systems smoothly using light-based setups during their busiest seasons.
Cost and Implementation Considerations
Installation and Equipment Needs
You’ll need proper electrical infrastructure to support LED indicators and integrate sensors with your Warehouse Management Software.
At Left Coast Electric, we design and install complete systems – from custom internet wiring layouts to energy-efficient lighting setups that support modern automation tools.
Our team ensures your system meets code, and we keep disruptions low, so your business keeps moving.
Budget and ROI Expectations
Start-up costs can feel steep, but the payoff often comes within the first year through time saved and errors avoided.
Tracking these wins isn’t guesswork – most clients calculate their return based on fewer mis-picks, faster cycles, and fewer hours worked per order.
We work closely with businesses to plan for long-term efficiency benefits from the start.
Energy Efficiency and Sustainability Gains
Modern Pick to Light systems paired with LED technology consume up to 75% less energy than traditional lighting solutions, according to the U.S. Department of Energy. By integrating energy-efficient components and smart controls, businesses not only reduce operational costs but also lower their environmental footprint.
At Left Coast Electric, we prioritize sustainable designs that align with green building standards, helping you achieve both performance and sustainability goals without compromising productivity.
Pick to Light Compared to Other Systems
Put to Light vs Pick to Light
Both systems use visual signals to guide warehouse staff, but they serve different purposes:
- Pick to Light: Directs workers to the exact location of each item required for an order. It is best suited for high-speed order picking where accuracy and speed are critical, such as e-commerce or retail distribution centers.
- Put to Light: Works in reverse. Instead of guiding workers to pick items, it shows where to place items once they’ve been picked in bulk. This is ideal for order sorting and consolidation, such as processing returns or distributing mixed items into multiple smaller orders.
Many modern warehouses use both systems together to streamline order fulfillment from start to finish.
At Left Coast Electric, we design and install electrical and control setups that support both technologies, helping you choose the right system for your workflow.
Voice Picking and Other Alternatives
Voice Picking: Workers receive instructions through wireless headsets, freeing up their hands and eyes. This method works well in dimly lit areas or when workers need to focus on handling delicate items. However, it can be slower for warehouses with high-volume or multi-item orders, where speed is critical.
Mobile Device Picking: Using handheld scanners or tablets offers flexibility and mobility, making it ideal for warehouses with frequently changing layouts or products. But constant screen checks and device handling can slow workflows and increase fatigue over long shifts.
Pick to Light: Light-based systems deliver real-time, visual guidance directly at the pick location, minimizing errors and maximizing speed. It is particularly effective in high-velocity order environments, like e-commerce, pharmaceuticals, or retail fulfillment centers.
At Left Coast Electric, we design systems that can integrate any combination of these technologies, tailoring the solution to your warehouse’s workflow, accuracy goals, and speed requirements.
Industry Applications and Real-World Use
Sector-Specific Uses
E-commerce centers benefit most, especially during flash sales and peak shipping times. Items move out faster and with better accuracy.
We’ve worked in retail environments where pickers work across multiple channels. Pick to Light keeps inventory accurate and workflows unified across online and physical orders.
Our lighting and electrical systems were designed precisely for these fast-paced demands.
Integration with Smart Technologies
Smart facilities pair Pick to Light with robotics and real-time analytics. Integration with Industrial IoT brings new ways to manage movement, efficiency, and stock levels.
Our commercial lighting controls are prepped for these advances, so you’re ready, no matter the system IQ.
For example, we use energy-efficient LED systems that work with motion sensors and automation tools that reduce energy usage and maximize uptime.
Frequently Asked Questions
What is the Pick to Light experience like for workers?
Workers follow glowing lights that show them exactly which shelf and how many units to pick. It reduces confusion and boosts speed. Most find it less stressful than traditional methods.
Is there a PDF or visual example of Pick to Light?
Yes, we can provide examples during our electrical planning consultations, including lighting placement and visual layouts tailored to your space.
Can Pick to Light be used in manufacturing setups?
Absolutely. Many assembly lines use Pick to Light for kitting and part selection. We’ve helped install systems just like this in local facilities.
What does the average system cost to install and maintain?
One of the advantages of Pick to Light technology is its low ongoing maintenance cost. Thanks to durable LED lights and minimal moving parts, annual maintenance typically amounts to 1–2% of the initial installation cost, covering occasional sensor replacements and software updates.