With pack-to-light or put-to-light systems there is a requirement to set up a central processing area, which can result in the design of a new layout and the introduction of further equipment. In terms of systems, put-to-light technology requires order consolidation and a batch pick of products. Part pallets or cases will need to be returned to stock if stores do not order in complete cases or the total number of units ordered does not equate to full case quantities. Pack or put to light can be more dynamic and works well with cross-dock operations where product can be received, allocated, picked and dispatched on the same day if required. Retailers have started picking sequences that duplicate store layouts, enabling retail staff to replenish shelves efficiently.
Comparisons
Earlier we read a single-pick operation where the picker collects all the items for a particular order and then takes it to dispatch prior to picking the next order. Picks can be made from a floor-level pick face or, if there are significant numbers of SKUs and too few floor locations, from a higher-level pick face. Now, we have a two-stage process where product is picked in bulk, for example by batch, followed by a sortation process into individual orders. Although in two stages, the pick rates are reasonably high and it also includes a double check of items and quantities, thus improving accuracy. Put-to-light systems use batching to collect all the items for specific orders. In section three we have the use of carousels, conveyors, few racks and fully automated AS/RS systems. Utilizing this form of picking, we see pick accuracy rates increasing together with the ability to handle large numbers of SKUs and items.
