What is Pick-by-Light?

Pick-by-light has been considered the epitome of efficient order picking for years: lights on shelf compartments indicate which items are to be picked and in what quantities. The employee picks the item, confirms by pressing a button—done. Fast, precise, paperless. But anyone who believes that pick-by-light is the answer to all efficiency problems in the warehouse has rarely seen everyday industrial life up close.

Because pick-by-light is not a sure-fire success. It is a tool – and like any tool, it only works reliably when it is embedded in a clean process. In many companies, the supposed efficiency fails precisely where the system is supposed to shine: in the interaction between technology, people, and organization.

Basic principle – light instead of lists

The system replaces paper-based or scanner-based picking with visual signals. A display with an LED light and confirmation button is mounted above each storage compartment. As soon as an order is active, the compartment lights up, the quantity appears on the display, the picker removes the goods, and confirms the process.

The idea: error reduction and time savings. No searching for items, no scanning, no paper lists. In theory, this is an ideal solution for fast and recurring picking processes – for example, in assembly supply, spare parts logistics, or e-commerce.

In practice, however, it has been shown that the benefits depend less on the technology than on discipline in the process. If storage locations are incorrectly maintained, items are incorrectly labeled, or orders are unclearly structured, the light will still illuminate, but it will point to the wrong location.

Industrial use—where repetition counts

In industrial intralogistics, pick-by-light shows its strengths wherever items are regularly picked in defined quantities. Typical areas of application are small parts warehouses, picking zones for assembly lines, or material provision with high throughput.

Advantage: The system is quick to learn and virtually language-independent – ideal for multi-shift operations with changing personnel. The error rate drops noticeably because visual guidance is more intuitive than number codes on paper or displays.

However, pick-by-light is not suitable for every warehouse. In environments with frequently changing items, variable storage locations, or large item ranges, the system becomes inflexible. Every restructuring means conversion, cabling, and adaptation—an effort that is often underestimated.

Cost-effectiveness – figures that are rarely heard honestly

Suppliers like to advertise performance increases of 40 percent and amortized system costs in less than two years. This may be true – in standardized, stable warehouse environments. In dynamic, seasonal, or small-scale structures, however, the calculation quickly changes.

The truth: ROI depends less on technology than on organization, master data quality, and process discipline. Anyone who installs pick-by-light without first revising their own warehouse concept is simply digitizing the old mistakes—only faster.

Before investing, an experienced logistics manager therefore does not check whether the lights are working, but whether the underlying processes are stable enough to deserve the light.

People and systems – who leads whom?

One of the most overlooked issues is people. Pick-by-light systems work excellently with trained, attentive staff. They work poorly when motivation, training, or attention are lacking. One wrong button press is enough for the system to proudly document a “successful pick” – even though the item is in the wrong box.

Here, too, the technology does not reduce the need for leadership; it makes it more visible. Good warehouse managers know this. They rely on regular process controls, clear responsibilities, and real-time monitoring instead of relying on the “infallibility” of the system.

Comparison and classification

Pick-by-light is part of a whole family of paperless picking systems. Pick-by-voice uses voice input, pick-by-vision uses augmented reality, and put-to-light supports returns or sorting processes. No system is better per se – the decisive factor is the intended use.

Pick-by-light excels where speed, ergonomics, and low error rates are priorities. Where flexibility and scalability are important, wired systems quickly reach their limits. The future therefore lies less in pure light systems and more in hybrid approaches that combine visual guidance with mobile devices or wearables.

Critical perspective – technology as a fig leaf

In many projects, pick-by-light serves as a symbol of modernity: flashing shelves, illuminated displays, impressed visitors. But the real yardstick is sobering: does the system deliver reliable output, does it reduce error rates, does it pay off economically?

Too often, its introduction is understood as a technical project rather than an organizational one. The result: light-emitting diodes without a concept. Yet the most critical step would be the simplest – an honest assessment of the process before the first cable is laid.

Because if you take the “light” in the name too literally, you risk only shining on the surface.

Conclusion – A precise tool, not a miracle cure

Pick-by-Light is a powerful tool when used with expertise: fast, intuitive, precise. In stable warehouse structures, it significantly improves throughput, ergonomics, and quality.

But anyone who sees it as a technological promise without examining processes will be disappointed. The system reinforces what is already there—good organization or bad. It brings light into the warehouse, yes—but it also illuminates weaknesses.

And that is perhaps its greatest value: Pick-by-Light forces companies to take an honest look at their logistics. Those who use it will benefit. Those who only purchase the technology are buying themselves a shining alibi.