When distribution centers are looking to increase production and accuracy, it is common for them to consider the picking to lights (PTL) method. Rather than having each worker independently read and fill the order before sending it on to the next section, the operation is gauged by flashing lights and an LED display for each individual automated order ticket or order zone.
Environment
PTL operations are most efficient in an order picking distribution center, as opposed to a manufacturing assembly plant. Rather than putting parts together, the concept is simply one of filling orders accurately. This can be used in conjunction with lean storage practices to reduce the amount of space needed and increase the number of units moving through the distribution center.
Purpose
PTL systems are frequently used for warehouse storage and distribution centers with very high volumes, multiple choices and low accuracy affect profitability and efficiency. By tracking each ticket through the process, each worker is responsible for their own work. This reduces miscommunications and misunderstandings between workers. It also puts accountability and responsibility on the worker to accurately count each unit.
How It Works
The concept of picking to lights is simple. Each product or bin is equipped with a light mechanism, button and number display. As the ticket barcode is scanned in through a handheld or stationary device, the lights and numbers for each product illuminate. As each part of the request is filled, the worker counts the specific number of items, puts them in the carton and turns off the light upon completion. When the ticket is complete, the carton is moved to the next station. For added efficiency, this is often done through a roller conveyor system. Conveyor systems may be set up for empty carton return, order completion or forward movement to the next order picking zone.
Considerations
When there are several components to the order in a large space, the floor may be divided into pick zones. Each person in each zone is responsible for a particular area or product, nothing else. As these portions are completed, the carton is moved to the next zone to fill the next portion of the ticket request. When there is not enough room or there are too few products to merit zones, each order picker is responsible for one ticket from start to finish. When it is complete, this is moved via gravity conveyor to the next department in the distribution center.
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In the center of distribution methods such as reading and filling orders is less efficient, because it was too long and uncertain, then the method is very good lighting, using LED that flashes for each booking tickets for individual orders or zone orders. And in terms of its environment as well if not using methods lamp (LED), then the amount of space needed is not enough and also the number of units that move very long time in the presence of multiple choice and low accuracy that affect the profitability and efficiency. And also if it does not use a method lamps (LED), each person will work out of control, so that the production process becomes longer because it is very inefficient. But if we use the method of lights (LEDs), the production process will be very efficient because it can increase production and accuracy, so each order will be flashing lights with LED display. So that each worker is responsible for their own jobs and reduce the amount of space needed and increase the number of units moved. It also makes accountability and responsibility on workers to accurately calculate each unit. With a simple concept that every product has a button, the mechanism of light and display number. So all of product company should use the method of lighting that makes the company more efficient in producing a product.Many benefitscanwe catchwhenwe readthe articlegoodforengineersorstudents. Good luck.
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