Warehouse and Logistics Customer
Manufacturing Execution Pick to Light Project
Going beyond a traditional pick to light system, our team provided a complete manufacturing execution system to streamline a local Warehouse and Logistics Company’s custom kit orders.
Our team installed signal lights above part bins on either side of a large aisle in the customer’s warehouse. To start the process, an operator selects an order from the production schedule sent from the manufacturing facility. As the operator progressively walks down the kitting aisle they are directed in sequence via a light above each bin to the parts that need to be picked. This improves operator efficiency, accuracy, and productivity by minimizing the need to walk up and down the aisle erroneously or rely on a manual list or order.
When the operator picks each item and touches the light, which serves as an optical touch sensor, the system re-cords that the part has been taken. When all of the parts have been picked, the system automatically completes the order, records the picked items, and prints a pick ticket including shortages for use at the manufacturing line. The pick to light system is integrated with the customer’s ERP system allowing for inventory management. If there is a part shortage, mis-stock, or other error, the operator can push a button which notifies the inventory control system.
The system then logs the information and dispatches a forklift to replenish the stock. This allows our customer to track occurrences and mitigate future errors, thereby improving inventory management, mitigating waste, and reducing office manpower and manual entry.
A unique benefit to our pick to light system is that it can be easily changed after implementation. A traditional pick to light system is generally hard-lined and is not adaptable. Within our system, our customer is able to quickly and easily add or change part or bin locations to further increase efficiency and adapt to the ever-changing demand.
Overall, the system has helped improve operator efficiency so much that the customer was able to eliminate a shift and relocate 15+ employees.
Aftermarket Solutions E-Commerce Site
Hoping to lower their waste and be more socially responsible, our team helped develop and implement an e-commerce system to sell scratch and dent truck parts. If a part fails the customer’s stringent quality standards, it is barcoded into the system. Once in the system, it is then compared to inventory and added to the e-commerce site and sold to the public. All part and sale date information is logged for future comparison and use.
Since implementation, the aftermarket solution e-commerce site on has sold on average half a million dollars a month in parts that would have otherwise become scrap.
Pick to light, P2L, Kit Orders, Custom Orders, Warehouse, Distribution, Efficiency, Productivity, Accuracy, ERP, Inventory Management, Manpower, Optical Touch Sensors