How to sort selected items using put-to-light

Often referred to as “pick-to-light in reverse,” a put-to-light system uses light modules that direct operators to the correct location to sort, or “put,” items into. (As opposed to a pick-to-light system, where lights direct operators to stock keeping unit/SKU locations to select, or “pick,” items.)

Scan batch wave label on tote or on batch order paperwork in tote of mixed SKU merchandise.

Select and scan individual items from the tote. A light will illuminate for the unique order requiring that product.

Put the item to the directed location and press the dome light to confirm completion of the task. Repeat the process with all items in the tote until the batch wave has been fully sorted.

Optional pack-out lights will illuminate on the opposite side of the workstation for each completed order that can be pulled for packing.

Put-to-light process

One of the most popular applications for put-to-light systems is sorting of batch picked products into individual orders. Batch picking is the process of picking multiple orders simultaneously during each pass through the warehouse. This optimizes fulfillment operations with a high number of SKUs and long pick paths. Batch picking works best in environments where products and orders are smaller, enabling pickers to pick into several boxes traveling together on a single cart.

Downstream from the picking process, the picked products must be sorted and matched to their appropriate order. Traditional batch processes utilize carts that travel to pack stations. There, items are manually sorted by reading pick tickets, shipping or other paper lists. This approach is slow and prone to mistakes.

If your products feature bar code labels, then a put-to-light system delivers a faster and more accurate way to execute this sortation. With put-to-light, the operator simply grabs an item and scans the label with an radio-frequency (RF) terminal. Lights illuminate at the put locations requiring that item, and indicate the quantities needed to fill the order. Items are moved from the carts to a dedicated space in the put station and presses a button on the light module to indicate the action is complete. The process repeats until the orders are completed.

How put-to-light integrates with your host system

In a light-directed sortation process, there is an interface between the put-to-light software and the user’s host enterprise resource planning (ERP), warehouse management system (WMS), manufacturing execution system (MES) or other software. The put-to-light system will download orders from the host; this data can often be shared in a variety of file formats.

From there, the put-to-light software tools manage the process, from creating operator work plans to configuring different modes and methods of sorting batches. The put-to-light software also addresses exceptions, such as when a scanned stock keeping unit (SKU) is not found in the order, shorting a SKU or custom order completion is necessary to complete the process.

During daily operations operators scan themselves into to their assigned put work station to track their daily productivity. During the sortation process operators press a confirmation button on the light module when puts for the scanned, active product to that location are complete. This transactional data is stored in a database, and the software provides advanced reporting tools enabling granular views of a facility, area/station or employee.

E-commerce Order Fulfillment Brochure

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Read how LP Put can provide high-speed light-directed order sortation for you.

Put Walls Datasheet

► LEARN MORE

Put walls, put workstations and other put-to-light solutions offer major operational efficiency gains including increased speed, accuracy and productivity.

Put-to-Light Demo

► Dual Sided Put Wall Demo

See a short, step-by-step demonstration of a tote of batch-picked items sorted into individual direct-to-consumer orders, ready to ship.

Put-to-Light Video

► System Introduction Demo

See a tote of batch-picked, mixed-SKU merchandise be sorted into individual direct-to-consumer or e-commerce orders. When orders are complete, lights on the other side of the put station illuminate for pack-out alerts.

Put-to-Light: E-commerce Order Fulfillment

► Trans World Entertainment

Trans World, a music and media retailer, uses Lightning Pick’s put-to-light for faster, more accurate e-commerce order fulfillment. LP Put is tightly integrated with their WMS and a new shipping software to provide a complete sort-and-ship solution.