Pick-to-Light-IconWarehouse/Distribution Picking and Sortation System Solutions

Brock applies Pick-to-Light, Put-to-Light, Voice and RF technology solutions to semi-automate manual picking and sorting processes. This is to improve order accuracy, increase rate per hour, and to eliminate the need for specialized training that is often required for manual sort processes.

Pick-to-Light

Pick-to-light systems allow operators to fill specific customer orders in an efficient manner. The following is an example of a pick-n-pack process:

  1. Bins with bulk stock of items are placed in specific “Zones”.
  2. A shipping carton used to pack a customer purchase order is placed on packing lane in a central location.
  3. An operator scans the barcode on the Shipping Carton.
  4. The bulk stock bins light up with a corresponding order quantity.
  5. The operator grabs the required quantity from the stock bins and confirms the transaction.
  6. The operator places the items into the Shipping Carton.
  7. After all the lights are addressed from the first zone, the Shipping Carton moves to the next zone.
  8. A closeout confirmation procedure is performed at the end of the picking lane.
  9. The shipping carton is placed on larger sorter for sortation to its final destination.

Put-to-Light

Put-to-Light systems allow operators to fill customer orders efficiently by the way of light buttons and numbered displays. The following is an example of the Put-to-Light process:

  1. Shipping cartons are set up in multiple locations for customer purchase orders.
  2. A bulk inventory item is brought to a central picking lane.
  3. Using mobile technologies, operators are able to scan the barcode of the bulk inventory item.
  4. Lights will turn on by each shipping carton that requires the inventory item and quantities will be displayed.
  5. The operator fills the shipping carton with the items from the bulk inventory container and confirms the transaction.
  6. Once the operator addresses all lights, a new bulk inventory item is brought to the central picking lane.
  7. This process continues until all items have been packed in the shipping cartons.
  8. Shipping cartons are placed on larger sorter for sortation.

Sort-to-Light

For larger items that have been presorted and need a finer sort at the end of a chute, light systems may be used to direct operators to semi-automate a manual sort process. The following is an example of the Sort-to-Light process:

  1. Shipping Containers are set up at the end of a chute and assigned items through a sort plan.
  2. An item is sorted on a shoe sorter, cross-belt sorter, etc. to a specific chute.
  3. The operator is able to scan the item barcode with an RF mobile device.
  4. The light will illuminate above the shipping container where it is to be sorted. (The application on the mobile hand scanner can also reveal other important details about the item for validation purposes.)
  5. The operator puts the item into the correct shipping container and repeats the process.

System Benefits

  • Allows operations to better utilize staff by enabling employees to handle multiple processes throughout the facility
  • Minimizes human error in the picking/sorting process
  • The operator is able to scan the item barcode with an RF mobile device.
  • Increases speed of manual sort process

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