| Written by Mark Buzinkay
A challenge is a window for opportunities
In a world of lean principles, safety regulations and productivity targets, we often forget that the reality in many plants is far different from the ideal. Just imagine the following scene:
In a busy manufacturing plant, workers scramble across the floor, trying to keep up with production demands. An assembler waits impatiently at his workstation, tapping his fingers on the workbench because the necessary components haven't arrived. Nearby, a forklift driver rushes past with a pallet of materials, but they're the wrong parts, leading to frustrated shouts from the team, and he has to turn around. In the storage area, a worker frantically flips through paper lists, searching for an item that should be there but isn't. Supervisors pace between stations, answering questions and attempting to fix mistakes that continue to slow down production, but the line stops and starts unpredictably, creating bottlenecks that ripple through the entire process...
This is less than optimal. However, this is not unusual. However, proactive measures are needed to fix this. One of them could be to do a Gemba walk. A Gemba walk is a valuable tool in the hands of a plant manager: Observing processes is the entry point to understand problems and to get ideas on how to fix them.
Intralogistics and the case for PTL systems
Gemba walks may reveal many small and big issues. In manufacturing, one of the frequent problem zones is intralogistics or the task of supplying workstations with the right items at the right times and in the right place.
A plant manager might consider implementing a pick-to-light (PTL) system when facing chronic inefficiencies that disrupt manufacturing operations. These inefficiencies could stem from errors in picking, delays in order fulfilment, excessive training time for new workers, safety concerns, and production bottlenecks.
One of the most common issues that PTL can address is the high error rate in picking and assembly. In many manufacturing environments, workers rely on paper lists or screen-based systems to locate and pick components. This approach often leads to mispicks, incorrect assembly, and ultimately, defects in the final product. When errors occur frequently, they result in costly rework, scrap, and customer dissatisfaction. PTL systems eliminate these mistakes by guiding workers with visual indicators, ensuring they always select the correct parts. This level of accuracy minimizes quality issues and reduces the need for time-consuming inspections or corrections.
In addition to improving accuracy, PTL systems can also help resolve slow order fulfilment and production bottlenecks. In traditional manual picking processes, workers spend significant time searching for the right items, navigating inefficient workflows, or double-checking their selections. These inefficiencies slow down material handling and prevent production lines from running smoothly. By integrating PTL, operators receive instant visual cues directing them to the correct part, reducing search time and improving workflow efficiency. As a result, order fulfilment speeds up, and manufacturers can consistently meet production targets without relying on overtime or additional labour (see also: auto identification technology)..
Training new workers is another major challenge in high-turnover industries. Conventional picking processes require extensive training before an employee becomes proficient, leading to inconsistent performance and prolonged onboarding periods. PTL systems significantly reduce the learning curve because they provide clear, intuitive, language-independent guidance. New employees can quickly adapt to the system without needing extensive instruction, allowing them to become productive faster and reducing the overall burden on training managers.
Safety is also a critical concern in manufacturing, and manual picking errors can contribute to workplace accidents. When workers mistakenly pick heavy or hazardous items, they may strain themselves or improperly handle dangerous materials. PTL improves safety by ensuring that employees pick the correct items in the correct sequence, reducing the likelihood of accidents. Additionally, many PTL systems offer hands-free operation, allowing workers to focus on handling materials safely rather than being distracted by scanning or paperwork.
Inefficient labour use in picking and material handling is another chronic issue in many factories. Without a structured system, workers may spend unnecessary time searching for parts, leading to the underutilization of available labour. PTL systems optimize workforce distribution by clearly indicating where work needs to be performed, enabling plant managers to allocate resources more effectively. This results in higher productivity with the same labour force, reducing the need for additional hires or costly overtime.
In many manufacturing plants, production downtime is a recurring issue due to missing or misplaced components. When operators cannot find the required materials, production lines may stop, causing delays and financial losses. PTL prevents these disruptions by ensuring that parts are picked accurately and efficiently. The system also provides real-time feedback, helping supervisors quickly identify and address any shortages before they impact production.
Another major problem that PTL can solve is poor inventory visibility. In traditional systems, tracking material flow can be challenging, leading to overstocking, understocking, or misplaced items. PTL integrates seamlessly with Warehouse Management Systems (WMS) and Manufacturing Execution Systems (MES), providing real-time inventory tracking and ensuring that the right materials are available when needed. This level of visibility reduces excess inventory costs and improves overall supply chain efficiency.
However, cost reduction is another key benefit that plant managers should consider when evaluating PTL. Frequent picking errors, production delays, and excessive rework contribute to high operational costs. PTL helps reduce these costs by improving accuracy, minimizing waste, and ensuring efficient material flow. Additionally, the increased speed and productivity provided by PTL can lead to a rapid return on investment, making it a cost-effective solution for plants struggling with inefficiencies.
Scaling production without increasing complexity is often a challenge for growing manufacturers. As production volumes increase, manual picking processes may struggle to keep up, leading to extended lead times and operational slowdowns. PTL systems are easily scalable and allow managers to reconfigure picking stations quickly to accommodate higher production demands. This flexibility makes it easier to handle growth without disrupting existing workflows.
Finally, as factories transition toward smart manufacturing and Industry 4.0, automation and real-time data integration become increasingly important. Many manufacturers struggle with outdated manual processes that do not align with their long-term digital transformation goals. PTL can be integrated with robotics, IoT devices, and AI-driven analytics to create a highly automated and data-driven operation. By incorporating PTL systems, manufacturers can take a major step toward optimizing their factories for the future.
How do you integrate PTL systems into manufacturing processes?
Integrating PTL systems into a manufacturing environment requires careful planning to ensure that they align seamlessly with existing processes and IT infrastructure. The implementation phase begins with identifying the specific areas where manual picking inefficiencies are causing bottlenecks, errors, or delays, as described above. Once these critical areas are pinpointed, PTL hardware, such as light modules, transponders and barcode scanners, is installed at designated picking stations, storage racks, material containers, or assembly lines. The system works by illuminating specific lights to guide workers to the correct locations, ensuring that the right materials are selected in the proper sequence.
However, it is essential to synchronize PTL systems with the production line's workflow. In a typical scenario, PTL is deployed in material-picking areas where workers need to gather components for assembly or kitting. As production orders are received, the system automatically activates lights corresponding to the required parts, allowing operators to quickly locate and retrieve them. This eliminates the need for printed picking lists and reduces reliance on memory or manual searching. Once an item is picked, the worker confirms the selection by pressing a button or scanning a barcode, signalling the system to move on to the next item. This process speeds up material handling and ensures that parts are picked in the exact sequence required for efficient assembly.
How do PTL systems collaborate with IT systems?
For a factory to fully leverage the benefits of PTL, integration with its IT infrastructure is crucial. The system needs to connect with the factory's Manufacturing Execution System (MES), which coordinates production activities in real time. By integrating PTL with MES, manufacturers can ensure that picking processes align with production schedules, preventing material shortages or delays. MES can trigger PTL commands based on real-time demand, ensuring that the right parts are available precisely when needed.
Additionally, PTL systems integrate with Enterprise Resource Planning (ERP) software, which manages overall business operations, including inventory, procurement, and supply chain activities. By linking PTL with ERP, inventory levels are automatically updated when items are picked, reducing the risk of stock discrepancies and enabling just-in-time replenishment. This helps manufacturers maintain lean inventory practices while ensuring that production is never stalled due to missing components.
Another critical integration point is with the Warehouse Management System (WMS), which controls storage, retrieval, and movement of materials within the facility. PTL systems enhance warehouse efficiency by streamlining order fulfilment and reducing search times for stored items. When integrated with WMS, PTL can dynamically adjust picking priorities based on demand fluctuations, ensuring that high-priority orders are processed first.
To achieve seamless communication between PTL and these IT systems, factories typically use standard industrial communication protocols such as REST APIs. These allow PTL systems to exchange data with MES, ERP, and WMS in real-time, ensuring that every material movement is accurately tracked and logged.
FAQ: PTL Systems
How does a pick-to-light (PTL) system work?
A PTL system uses illuminated indicators (e.g. LEDs) at picking locations to guide workers to the correct items. When an order is initiated, lights at designated bins or shelves activate, showing the worker where/what to pick. Once the item is retrieved, the worker confirms the action by pressing a button or scanning a barcode. This real-time process ensures accuracy, speeds up picking, and reduces errors in material handling.
What are the key benefits of implementing PTL systems in manufacturing?
PTL systems improve accuracy, reduce picking errors, and accelerate order fulfilment. They also minimize the need for extensive training, as visual guidance makes the process intuitive. Additionally, PTL systems enhance productivity by reducing search time and optimizing material flow. When integrated with IT systems like MES, ERP, or WMS, PTL ensures real-time inventory updates, prevents production delays, and supports lean manufacturing principles.
Can PTL systems be integrated with existing factory IT infrastructure?
Yes, PTL systems can seamlessly integrate with Manufacturing Execution Systems (MES), Enterprise Resource Planning (ERP) software, and Warehouse Management Systems (WMS). These integrations allow real-time data exchange, ensuring synchronized inventory tracking, optimized production schedules, and improved material availability. Communication protocols such as REST APIs enable smooth connectivity, making PTL a scalable and future-proof solution for smart factories.
Takeaway
The reality in many factories often falls short of lean manufacturing ideals. Production delays, missing components, and inefficient material handling create unnecessary bottlenecks. By improving intralogistics, factories can move closer to streamlined operations, reducing wasted time and effort. Pick-to-light systems offer a solution by optimizing material flow and increasing efficiency. When integrated seamlessly with IT infrastructure, they enhance production scheduling, inventory tracking, and labour management. To learn more about achieving higher efficiency, explore Pick by Light System: How to Get More Efficiency? and consider solutions like Asset Agent for intelligent intralogistics automation.
Delve deeper into one of our core topics: Real time location systems
Glossary
In industrial contexts, scaling refers to a system's ability to handle increased workloads or production demands efficiently. A scalable manufacturing process can expand output without compromising quality or performance, often by adding resources like machinery or labour. This capability is crucial for companies aiming to grow and adapt to market demands while maintaining operational efficiency. For a comprehensive understanding of scalability in business operations, refer to Investopedia's article on scalability. (2)
Sources:
(1) https://mau.com/2023/04/11/the-hidden-cost-of-instability-and-ineffective-processes/
(2) https://www.investopedia.com/terms/s/scalability.asp
