Manage productivity and maintenance with put- and pick-to-light system software

-- Modern Materials Handling, 8/1/2003

Basic software that is provided with pick-to-light systems as well as their close cousins, put-to-light systems, "will light the lights and produce some reports for management," says George Feigley, manager of logistics information technology, Siemens Dematic, (616-913-6200). Yet that's only the tip of this iceberg. "Software really is the critical element in these systems," he adds.

By having software with greater capabilities and integrating it into a good warehouse management system, the pick- and put-to-light technologies can give warehouse and distribution center managers a powerful array of supervisory tools.

"You can make the distribution center incredibly efficient through manpower planning," says Ralph Henderson, national sales manager, Kingway Material Handling, CAPS Division (603-772-2070). "Pick-to-light system software provides users with a rich data base that you could not get and easily use with a manual picking system." Software permits "a manager to calculate in a very short time how best to deploy his people." Software helps decision making on "how to balance the work loads on busy days with added picking personnel brought in from receiving, shipping, or other areas of the DC," he adds.

"Our customer wants software with enough robustness to track individual picker productivity as well as the work progress of a team of pickers involved in a specific wave pick in real time," says Tom Coyne, CEO, Diamond Phoenix (207-784-1381). So equipped, the customer can manage his manpower planning, Coyne says. "And he can find answers to such questions as, 'Do I need to staff my order pick module with five, ten or 15 pickers?'" Pick-to-light software also needs "to be easy to use and graphical,” he adds.

With the ability to track and report individual picker productivity, adds Kingway's Henderson, the data from the software can be compared against labor standards and trends, and used in incentive compensation. Just as a rising tide lifts all boats, he continues, picker productivity can rise through use of the tracking and reporting modules of pick-to-light. "It goes with the old adage," he says, that, " 'what gets measured, gets done.'"

"Instead of managers making their best guesses, they get real-time updates through the software," says Stephen Legg, president, Real Time Solutions, an FKI Logistex company (510-985-6300). "The true beauty of these systems," he adds, "lies in the real-time knowledge." Managers receive information "so they can pre-plan and be proactive as opposed to being reactive," Legg says.

"The vast majority of warehouse management systems can drive a pick- or put-to-light system," observes Ed Romaine, director of marketing, Remstar (800-639-5805). "But can they manage them?" he asks. Another level of software geared to the requirements of the technology and its proper usage may be necessary.

"Algorithms in the software," continues Romaine, "can determine the best storage system density, and thus save on floor space utilization. Or the algorithms can be used to maximize SKU [stock keeping unit] distribution." Similarly, the software can help managers slot their systems properly, do lot tracking, and help make decisions on inventory levels, he adds.

Through use of robust pick-to-light software, moreover, storage systems can be slotted so that the fastest movers will be stored in locations in the "golden zone," or where these items are located in the most ergonomic positions for pickers to pick them from, adds Siemen's Feigley.

When load weight, OSHA regulations and productivity issues become business concerns, adds Remstar's Romaine, organizations can combine pick-to-light with vertical storage systems, such as vertical lift modules and vertical carousels. They have the ability to deliver every SKU to the golden zone and without any walk and search time.

The software can be used to manage maintenance as well. Many pick-to-light software systems have self-diagnostic controls to help users proactively determine light or circuit problems, notes Romaine. Similarly, most pick-to-light hardware includes easy, plug-and-play modules which virtually eliminate system downtime.