Build2Light Light-Directed Error Proofing System at ProMat

Lightning Pick system reduces errors in parts picking, kitting and assembly

pick-to-light Build2light brand error proofing systemGERMANTOWN, WI (March 20, 2015) — Reliable and flexible, the Build2Light system utilizes light-directed picking modules to guide operators to the correct parts, quantities and pick sequences with higher levels of accuracy than paper-based picking methods. The system is designed, engineered and manufactured by Lightning Pick, a Matthews Automation Solutions’ brand, and will be displayed at ProMat 2015 in Booth 3903c.

Build2Light is supplied as a complete pick-to-light package. Precisely engineered, the automated system eliminates errors in critical manufacturing procedures such as kitting, assembly, error proofing, poka-yoke and sequencing, plus general parts picking. The product offers the same best-in-class Lightning Pick hardware options used in larger scale pick-to-light distribution and production installations worldwide. Ideal for operations requiring a finite number of processes, or when more complex processes require proof of concept prior to implementing a new system, Build2Light supports continuous improvement and Lean processes.

The system uses lights mounted on workstations, bin shelving or other material storage media. To use the Build2Light system, the operator simply scans the barcode associated with a specific set of tasks. When the barcode is scanned, the lights associated with the required parts illuminate. In addition, an optional image viewer displays part images and assembly instructions as a visual reference for operators.

Configurable from a catalog that features several available hardware options to fit specific application requirements, Build2Light can be flexibly configured to address a broad spectrum of operational challenges. All models feature a variety of indicator light colors, orientations and easy-to-read displays.

Further, Build2Light’s operation is powered by intuitive, easy-to-use software engineered for industrial use, explained Pete Gerbitz, Senior Account Manager at Lightning Pick. “Through the software, operations managers can easily create bills of materials (BOMs), recipes, jobs or orders and configure their best light-directed processes with minimal (or no) vendor or integrator support,” he said. “It’s also very easy to use, allowing facilities to bring new, seasonal or temporary employees quickly up to speed on how to interface with the system.”

User Robert Balstrup, manufacturing and facilities manager at Husco International’s Whitewater, Wisconsin location agreed. “Build2Light has been trouble-free with zero lockups and no down time with the system,” he said. “We’re also able to bring an operator over from a different line and have them assemble valves without any instruction. In the past this would take a day of training.”

Lightning Pick’s Build2Light demo system can be seen in action at Booth 3903c throughout ProMat 2015 in Chicago, Illinois—March 23-26, 2015. For more information on Build2Light, contact Joe Pelej at Matthews Automation Solutions at 262.250.2143, or by email at [email protected], or visit

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Lightning Pick, a Matthews Automation Solutions’ brand, delivers advanced pick-to-light, put-to-light, pack-to-light, batch picking carts, light sleds and other paperless picking, kitting, assembly and sortation systems from two locations in Germantown and Ixonia, Wisconsin. Our globally recognized automated technologies drive increased productivity, quality and efficiency across Lean supply chains—from manufacturing through order fulfillment. In 2014, Lightning Pick added the sales, support and service of all Pick-MAX light-directed products, formerly by IPTI.


Matthews Automation Solutions—a division of Matthews International Corporation—designs, manufactures and distributes a wide range of marking, coding and industrial automation technologies and solutions. Manufacturers, suppliers and distributors worldwide rely on Matthews’ integrated systems to identify, track, control and pick products at the highest levels of accuracy and throughput. For handling challenges in manufacturing, packaging or distribution, Matthews’ combined expertise delivers the integrated solution that meets an organization’s needs today and grows with them tomorrow. These automated and semi-automated marking, coding, control, sortation, picking and verification technologies and software streamline manufacturing, distribution and order fulfillment processes to maximize productivity.

The Matthews Automation Solutions’ family of brands includes Holjeron, Lightning Pick, Matthews Marking Systems and Pyramid.

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