• System description

    Work stations combined with Pick to Light

    This Pick to Light solution enables the implementation of semi-automatic manual workplaces. The PickVision individual workplace application enables process optimisation at the assembly workplace or packaging station.

    The goal is to achieve the zero-error strategy in the production and logistics process.


    For this reason, an ergonomic lean-production workplace tailored to the requirements of the worker is set up and combined with a PickVision system. The worker is guided via the software of the Pick to Light system.


    Stand-alone island solutions and connection to a higher-level control system (e.g. PLC, database, ERP, MES, PPS, etc.) are possible.

    The standard design of the
    work station comprises:

    • Ergonomic manual workplace by means of tried-andtested pipe racking system by G.S ACE
    • Pick to Light for process optimisation
    • Pick to Light software for parameterisation and connecting to third-party systems

    Possible expansions:

    • Worker guidance as assembly aid
    • Poka-yoke for error prevention
    • Connection of peripheral devices: e.g. scanners, cameras, scales, printers, screwdrivers, sensors and actuators, etc.
    • E-KANBAN system
    • Large displays for process visualisation: LED displays and industrial monitors
    • Remote access

    Assembly island combined with Pick to Light

    The assembly island consists of individual workplaces that are coupled to one another.

    The PickVision system and the digitalised worker guidance even allow inexperienced workers to carry out highly complex, interlinked production processes.

    At the same time, the „zero-error principle“ are at the forefront for high performance and quality.

    During the production process, scanners, screwdrivers, cameras, label printers, test systems, sensors, actuators and so on are integrated into the shelving.

    The PickVision system software manages the third-party systems and models the process procedure.

    The production island consists of:

    • Ergonomic workplace by means of tried-and-tested
      pipe racking system by G.S ACE
    • Pick to Light and Put to Light system for process optimisation
    • PickVision software for:
      - Worker guidance
      - Parameterisation
      - Connection to third-party systems
      - Plausibility testing
      - Recording trace data
      - Statistical evaluation

    Possible expansions:

    • Poka-yoke for error prevention
    • E-Kanban system
    • Large displays for process visualisation: LED displays
      and industrial monitors
    • Remote access
    • Automated guided vehicles and Spurmeise systems

    Picking on assembly lines via Pick to Light

    In this Pick to Light solution, picking modules and assembly workplaces are „married“ together. The picking area and the particular assembly workplaces are in separate locations.

    The error-free coupling of picking and provision of modules to the assembly workplace is the goal of this Pick to Light application.

    In this process, the picking trolley is led along the flow rack on a track. Both the picking trolley guide attached to the track and the flow racks are fitted with a PickVision system.

    The track guide and the picking trolley are „married“ by data during the picking procedure.

    Multiple workers can process order packages at the same time in the picking island. Individual components can be picked in series or in parallel with individual or collective acknowledgement.

    At the end of the picking procedure, the worker „decouples“ the trolley from the pick-up station and pushes it to an additional picking device at the corresponding picking place on the assembly line. After the trolley and its modules are checked and „married“ to the higher-level system, this triggers the withdrawal of the modules for the respective assembly procedure on the production line.

    The production island consists of:

    • Flow rack, picking trolley and assembly workplace by means of tried-and-tested pipe racking system by G.S ACE
    • Pick to Light system for process optimisation
    • Pick to Light software for:
      - Worker guidance
      - Parameterisation
      - Connection to third-party systems
      - Plausibility testing
      - Recording trace data
      - Statistical evaluation

    Possible expansions:

    • Poka-yoke for error prevention
    • E-Kanban system
    • Large displays for process visualisation: LED displays
      and industrial monitors
    • Remote access
    • Automated guided vehicles and Spurmeise systems

    Picking Cart with Pick to Light

    The Pick to Light cart combines all the components of the tried-and-tested Pick to Light system in one
    picking trolley. Poka-yoke via Pick by Light as a mobile application.

    Using the Pick to Light cart, multiple orders can be processed at the same time in a paperless and routeoptimised manner.

    The PickVision picking trolley can be designed individually according to customer requirements (number
    of levels and boxes).

    Each drawer on the trolley is fitted with a Pick to Light display. Data is transmitted via radio.

    The power is supplied via busbar or battery. For 24/7 operation, there are solutions for automatically loading the trolley at certain positions during travel.

    The compartments are filled with the required goods and serve as a storage/withdrawal compartment for an order.

    The correct withdrawal/storage location is confirmed either by additional Pick to Light displays on the shelving and/or by scanning the article or the storage compartment.

    If the article withdrawn/scanned is part of an active picking order, the light rings of the Pick to Light displays light up on the compartments of the picking trolley in which the article is to be stored or from which the article is to be withdrawn. At the same time, the quantity required is shown on the display.

    The operator confirms the storage/withdrawal using the acknowledgement button on the Pick to Light display. If all the storage compartments for this article are occupied or the withdrawal compartments for this workplace are confirmed, the employee is taken to the next withdrawal/storage location.
    This enables multiple orders to be processed in a single journey in a route-optimised manner.

    The standard design of the Pick to Light cart comprises:

    • Ergonomic trolley made of tried-and-tested pipe racking system by G.S ACE
    • Pick to Light for process optimisation
    • PickVision™ software for parameterisation and connecting to third-party systems

    Possible expansions:

    • Poka-yoke for error prevention
    • Connection of peripheral devices: e.g. large displays for process optimisation: LED displays and industrial monitors

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