Our team designed and implemented a pick to light system that used our Vehicle company’s ERP system to provide inventory control, data collection, and visual picks.

We provided a complete manufacturing execution system to streamline our customer’s inventory control system and custom packing orders. Our team installed lights above tire and wheel part bins on 32 aisles. To start the process, an operator selects an order from the production schedule. As the operator walks/drives a high-low down the aisle, they are directed in sequence via a light above each part pin to show the operator what parts are needed. When all of the parts have been picked, the system automatically completes the order, records the picked parts, prints a shipping label, and electronically invoices the customer.

The pick to light system also offers inventory management. In the case of a part shortage, mis-stock, or other error, the system logs the data and dispatches a forklift to replenish the stock. This allows our customer to track any issues and avoid future errors, thereby improving inventory management while mitigating waste.

The system also maintains a continuous live inventory. When parts are pushed through assembly they are tracked through to the vehicle. At any point, on any vehicle, a specific part can be tracked down to its serial number and manufacturer. With some of the parts have a limited shelf life, the inventory operates on a first in, first out basis, ensuring that older parts are used first. This allows for increased quality control, lower inventory waste, and the increased ability to recall faulty parts.