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Pick-by-Light in assembly – optimising processes efficiently
Pick-by-Light is a form of digital worker assistance that supports manual assembly using light signals. A Pick-by-Light system enables you to increase assembly speed, reduce the error rate and cut costs – whilst maintaining consistently high quality.
Assembly is an important step in manufacturing goods and producing industrial products that consist of several components. Precision, speed and quality are essential to ensure customer satisfaction and competitiveness. Pick-by systems allow you to ensure that your workers assemble the right parts in the right order without making mistakes or wasting time.
The pick-by-light production method and pick-by-light process enable sustainable cost reductions at a worker-assisted assembly workstation with an integrated pick-by-light system. With the SOMA flexAssistant worker assistance, you can set up an assembly line with a pick-by-light system that optimises the assembly and production process and reduces errors in manufacturing.
What is pick-by-light in assembly?
A pick-by-light system (or pick-by systems in general) is a form of digital worker assistance that supports the assembly process with visual signals. Lights are installed at the storage or assembly locations of individual components to indicate to the worker which part to pick up and assemble next.
The Pick-2-Light luminaires are controlled by a central control system that contains the assembly instructions for each product. As soon as the worker has picked up the correct part as instructed, the next step in the process is triggered automatically by the worker assistance system via a sensor, and the light is switched off.
The next light is then switched on until the product has been completely assembled. In this way, pick-by-light assembly ensures a consistent manufacturing process throughout.
Competitive advantage through pick-by-light at the assembly workstation
Pick-by-light systems facilitate precise and efficient material retrieval. Together with the pick-to-light application, they create competitive advantages in semi-automated and manual production environments by optimising order fulfilment and manufacturing processes in pick-by-light assembly.
Unlike voice-controlled or paper-based systems, pick-by-light systems use light signals directly at the assembly workstation. The signal tells the employee which component to retrieve. This visual cue reduces two cost drivers in the pick-by-light system: training costs and the error rate.
Employees are therefore able to work more quickly. The initial costs of introducing pick-by-light or pick-to-light may be higher than those for voice- or paper-based order picking; however, over the long term, they pay for themselves through higher productivity, fewer errors and a correspondingly high ROI (return on investment).
Get non-binding Pick-by-Light advice
Do you have questions about our worker assistance and pick-by-light system as individual solutions for your production? We are happy to help. Please contact me.
Your personal contact partner
Michael Penzel
Phone: +49 2355 50828-973
Email: m.penzel@soma.de
Pick-by-Light – Benefits for manual assembly
The pick-by-light system assembly workstation offers many advantages for manual or semi-automated manufacturing, production and assembly processes.
Increase productivity
Visual guidance in pick-to-light and/or pick-by-light assembly allows employees to work faster and more efficiently without having to spend a long time looking for the right parts. In addition, paperless manufacturing allows them to concentrate better on their actual task without being distracted.
Improving ergonomics
By adapting the lights to the ergonomic needs of the workers, physical strain is reduced at the pick-by-light assembly workplace. The lights can be designed in different colours and intensities to improve visibility and comprehension. They can also be positioned to avoid unnecessary handling movements.
Simplified onboarding
Thanks to the intuitive operation of the pick-by-light systems, new employees can be trained more quickly and easily in the task of the assembly line without having to manage long training sessions or instructions. This saves time and costs and increases the flexibility of staff deployment.
Error reduction
By clearly identifying the required parts, mistakes and incorrect assemblies are avoided. If an employee reaches into the wrong compartment, they are warned by an audible or visual signal from the pick-by-light system and can correct the mistake. This reduces waste and rework and increases quality.
Most important advantages
of pick-by-light and pick-to-light assembly
- Visual assistance and digital work instructions of assembly tasks as worker assistance for manual assembly
- Avoid production errors: Errors during assembly are recognised and made visible until they are corrected
- Runs with almost any hardware, as an industry-independent solution for worker assistance
- Intuitive worker assistance helps you be productive faster
- Complete process traceability of all work steps
- Information retrieval for optimisation of tools, materials or sequences even in complex processes
- SOMA at your side as an experienced partner in industrial production
Integrate Pick-by-Light systems and digital worker assistance into your assembly and production
In order to integrate a pick-by or pick-to-light system into your assembly, you must first create a few prerequisites, which we, as a solution provider and established system supplier with over 50 years of experience, implement together with you.
Analysis of your assembly processes and production requirements
To find the optimal solution for your requirements of a pick-by-light system, we first need to analyse and document your assembly processes. Together with our solution experts, we will answer the following questions: Which products are assembled? How many components are needed? What is the assembly sequence? How high is the number of variants? How often do the products or processes change?
From these results, we will jointly create a concept that meets your requirements for a pick-by-light system. Our team will then develop a cost-effective solution that supports and optimises your assembly processes. We will guide you through the entire process to ensure that the solution meets your requirements.
Installation and commissioning of the assembly line and pick-by systems
In order to integrate the assembly workstation or assembly line with pick-by-light system into your existing production, you need to carry out technical and organisational steps, which we develop together with you and our team of experts in a structured manner. Starting with the right software solution (with the flexAssistant software suite) that fits your production process and which meets the requirements of your assembly line.
The SOMA flexAssistant worker assistance system is an industry-independent digital worker assistance system that either adds the software component to your assembly line or maps a complete assembly workstation. We support you throughout the entire process in selecting and implementing the required components.
Optimise production and assembly with Digital Worker Assistance and Pick-by-Light
Digital worker assistance and pick-by-light systems are a modern and effective way to optimise assembly processes. Visual guidance allows you to improve the productivity, quality and ergonomics of your assembly while reducing errors, waste and rework. In order to successfully integrate pick-to-light systems into your production, we and our experts will work together to analyse the assembly processes according to your requirements and find a suitable and optimal assembly solution. With the flexAssistant assistance system with pick-by-light support, you can gain a competitive advantage and satisfy your customers.
See the assembly workstation with Pick-by-Light in action
Discover all the advantages of the SOMA flexAssistant worker assistance system in a short video. Our team offers you comprehensive advice and support in the implementation of your pick-by-light system. Our experts accompany you during the planning and implementation of the system and help you to optimise your assembly processes. The SOMA flexAssistant system is modular and can be expanded with various components. This allows you to adapt your system to your specific requirements.
What is the difference between "Pick-by-Light" and "Pick-to-Light" systems?
"Pick-by-Light systems" and "Pick-to-Light systems" are two similar methods based on the use of light signals. The main difference is that in the pick-by-light method, the employee collects the assembly parts from the compartments, whereas in the "pick-to-light" method, the order picker places the items in the compartments.
What is a Pick-by-Light system?
Pick-by-Light is a paperless assembly process (a concept also familiar from paperless order picking) in which the production worker is informed of the items to be picked via a display directly on the pick compartment.
The display consists of a clear light signal and a confirmation button or sensor, which the assembly operator uses to confirm the item has been removed and to transmit the stock change in real time to the warehouse management system or to the assembly assistance software (such as the SOMA flexAssistant Software Suite).
What is a Pick-to-Light system?
Pick-to-Light is the reverse procedure of pick-by-light. In this case, the order picker does not remove the item but places it into storage. Pick-to-light systems are usually used in two-step order picking.
In a first step, the goods are brought to the appropriate position individually by the picker. Subsequently, the storage is confirmed via the pick-to-light system. This enables a fast and efficient recording of the storage.
Get non-binding Pick-by-Light advice
Do you have questions about our worker assistance and pick-by-light system as individual solutions for your production? We are happy to help. Please contact me.
Your personal contact partner
Michael Penzel
Phone: +49 2355 50828-973
Email: m.penzel@soma.de
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