Digital Order Picking

Pick-to-Light: the biggest advantages of digital picking

September 4, 2026

ekko Knowledge
Pick-by-Light im Sequenz-Picking für die Automobilbranche und Industrie

Mispicks, time spent searching, paper lists: in manual picking, most errors are not caused by carelessness, but by unclear instructions. Pick-to-Light solves exactly that — using light signals directly at the shelf compartment that show every employee where to pick and how much, with no training required. In this article, we explain how the method works, the measurable benefits it brings, where its limitations lie, and what is important when implementing it.

What is Pick-to-Light? Pick-to-Light is a paperless picking method where light indicators on a storage or shelf compartment signal where an item should be picked from and in what quantity. The pick is confirmed by pressing a button and reported back to the ERP or warehouse management system in real time. In English, the method is known as Pick-to-Light — both terms refer to the same system.

How Pick-to-Light works, step by step

The principle is explained in five steps:
  1. A picking or supply order is received from the ERP, WMS, or MES system.
  2. The LED display on the relevant compartment lights up; a display shows the quantity to be picked.
  3. The employee retrieves the item — no lists, no scanning, no searching.
  4. The pick is confirmed via a confirmation button.
  5. The system reports the transaction in real time and switches to the next position.
In addition to picking, there is the reverse process known as Put-to-Light: here, the light indicates which compartment an item should be sorted into or distributed to — for example, during put-away or when distributing items across multiple orders. There is also a crucial difference in hardware: traditional systems are hard-wired, whereas modern systems like those from ekko use wireless radio modules that can be mounted on existing shelving without electrical installation and relocated at any time.

The seven biggest advantages of Pick-to-Light

1. Error rates drop drastically. Clear light signals replace the need to cross-reference part numbers and lists. In practice, error rates fall by up to 80 percent — every avoided mispick saves on rework, returns, and, in the worst case, a production line stoppage at the customer's site.

2. Picking becomes measurably faster. Without time spent searching or reading, picking performance increases significantly: one online retailer boosted their picking speed by 35 percent using the ekko Pick- and Put-to-Light system.

3. Training in minutes, not days. Anyone can follow the light from their very first shift — ideal for seasonal workers, temporary staff, and environments with high turnover. Training time and onboarding errors are almost entirely eliminated.

4. No more paper and lists. Pick lists, routing slips, and manual checking are a thing of the past. This saves not only on materials but, more importantly, eliminates the errors that occur during data entry.

5. Real-time inventory transparency. Every confirmation is immediately fed back into the ERP or warehouse management system. Inventory levels are accurate, orders are traceable, and bottlenecks are identified before they even occur.

6. Material flow becomes controllable. Pick-to-Light works not only in the warehouse but also for material supply at the workstation — and can be combined with eKanban to trigger replenishment automatically as soon as a bin runs low.

7. Work becomes more pleasant. Less searching, less uncertainty, less stress: employees consistently rate light-guided picking positively — an underestimated factor in times of skilled labor shortages.
pick-by-light

Where Pick-to-Light is used

Wherever speed and accuracy are critical: in order picking for retail and e-commerce warehouses, assembly supply in manufacturing, medical technology, and hospital logistics — and especially in the automotive industry, where components must reach the assembly line in precise sequence. A practical example: BMW uses ekko’s Pick-to-Light guided sequencing in twelve plants worldwide — from the material supermarket to the assembly line.
Average time savings in comparison:
Infografik der durchschnittlichen Zeiteinsparung durch verschiedene Picking und Kommissioniermethoden im Vergleich. Gemessen an Pick-by-Paper, Pick-by-Light, Pick-by-CMD und Pick-by-HUD.
The study shows that light-guided picking saves around one-third of the time per order compared to paper lists. While head- and cart-mounted displays were sometimes even faster in the test setup, smart glasses often fail in practice due to costs and user acceptance. That is why, in addition to Pick-by-Light, ekko also offers Pick-by-CMD: a method designed to follow the process, not the other way around.

Does Pick-to-Light have any disadvantages?

Yes — though most of these concerns relate to the traditional, wired generation of systems. The three most common objections:
  • High installation costs: Wired systems require every compartment to be electrically connected. Wireless radio modules eliminate this expense entirely — they are mounted directly onto existing shelving without the need for an electrician.
  • Inflexible during renovations: If the product range or shelf layout changes, wiring becomes a constant construction site. Wireless displays can be relocated in minutes.
  • One compartment, one display: Pick-to-Light is worthwhile where items are accessed frequently. For rarely moved items or very large product ranges, it is best combined with other methods.
In a comparison of methods, the rule of thumb is: Pick-to-Voice keeps hands free but requires training and becomes slower with high item density. Scanner-guided picking is inexpensive but is the slowest of the three methods. Pick-to-Light shows its strengths when many picks must be performed quickly and error-free in a confined space—such as in picking zones, at flow racks, and in sequencing.

Integration with ERP, WMS, and MES

A Pick-to-Light system is only as good as its integration. A seamless process is only created when orders arrive automatically from the management system and confirmations flow back in real-time. The ekko platform connects via open interfaces—including REST API, webhooks, and MQTT—to systems like SAP. The decisive difference compared to custom projects: processes are configured rather than programmed. New workflows, additional zones, or changed rules are just a setting, not a software project.

Implementation and ROI: How to get started

A phased approach has proven successful: first, a process analysis with clear goal definitions, then a pilot area—such as a picking zone or assembly line—followed by the rollout. It is important to involve employees early and choose a provider that offers modularity and open interfaces so the system can grow with your processes. It is economically viable very quickly: thanks to time saved and errors avoided, Pick-to-Light projects often pay for themselves in under twelve months—even faster with wireless systems, as installation costs are largely eliminated. We would be happy to show you what the numbers look like for your shop floor based on your specific processes.

Frequently asked questions about Pick-to-Light

What is Pick-to-Light?

A paperless picking method: light indicators on the shelf compartment show where and in what quantity an item should be picked. The pick is confirmed via a button and reported in real-time to the ERP or warehouse management system.

What is the difference between Pick-to-Light and Pick-to-Light?

None—both terms refer to the same system. "Pick-to-Light" is common in German-speaking countries, while "Pick-to-Light" has become the international standard.

What is the difference compared to Put-to-Light?

Pick-to-Light controls picking, while Put-to-Light controls sorting: the light indicates which compartment an item should be placed into—for example, during storage or when distributing items to orders. Both variants run on the same hardware.

How much does a Pick-to-Light system cost?

That depends primarily on the number of compartments and the hardware chosen. With traditional systems, electrical installation is required for each compartment; with wireless systems, this cost is eliminated, making the initial investment significantly lower. Most projects pay for themselves in under twelve months.

Can Pick-to-Light be retrofitted to existing shelving?

Yes. Wireless modules are mounted directly onto existing shelving without the need for electrical installation and can be relocated at any time if the layout changes.

Which industries is Pick-to-Light suitable for?

Wherever picking or material supply needs to be fast and error-free: automotive, mechanical engineering, logistics and e-commerce, medical technology, hospitals, and retail.
Would you like to test Pick-to-Light in your warehouse or production facility? Here you'll find ekko's plug-and-play solution — or talk to us directly.
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