How Pick-to-Light Reduces Picking Errors by 99.9%？
In modern warehouses, picking errors are one of the most expensive operational problems. A single mistake can lead to returns, reshipments, customer complaints, and wasted labor. As order volumes grow and SKU counts increase, relying on paper lists or handheld scanners often pushes error rates higher.
This is why more warehouses are turning to Pick to Light systems—a proven solution capable of reducing picking errors to 99.9% accuracy or higher.
Why Picking Errors Happen in Traditional Workflows
Before understanding how Pick to Light eliminates errors, it's important to see where mistakes usually occur:
* Misreading printed pick lists
* Selecting the wrong SKU from similar-looking products
* Skipping a line or picking the wrong quantity
* Scanning the wrong barcode in high-speed environments
* Fatigue during long shifts or peak seasons
Even with RF scanners or voice picking, human interpretation remains a major risk factor.
What Makes Pick to Light Different
Pick to Light systems replace interpretation with visual confirmation.
Instead of searching, reading, or listening, operators simply:
1. Follow illuminated lights on the shelf
2. Read the exact quantity displayed
3. Confirm the pick with a button or sensor
Each action is guided, verified, and recorded in real time.
1. Visual Guidance Eliminates Location Errors
One of the most common picking mistakes is selecting the correct item from the wrong location.
Pick to Light solves this by:
* Illuminating only the correct pick position
* Removing guesswork entirely
* Preventing operators from moving ahead without confirmation
The system physically directs attention, making wrong-location picks nearly impossible.
2. Quantity Display Prevents Over- and Under-Picking
Paper lists and voice instructions can be misunderstood, especially in noisy or fast-paced warehouses.
With Pick to Light:
* The exact pick quantity is displayed clearly
* Counts are confirmed at the shelf
* Multi-quantity errors are drastically reduced
This is especially valuable for piece picking and high-SKU environments.
3. Mandatory Confirmation Creates a Closed-Loop Process
Every pick in a Pick to Light system must be confirmed.
This closed-loop workflow:
* Prevents skipped picks
* Ensures tasks are completed in the correct sequence
* Sends instant feedback to the WMS
As a result, discrepancies are caught immediately instead of downstream.
4. Seamless WMS Integration Keeps Data Accurate
When Pick to Light is integrated with a Warehouse Management System (WMS):
* Orders are dispatched directly from WMS
* Pick confirmations update inventory in real time
* Error-prone manual data entry is eliminated
This synchronization ensures system data always reflects what actually happens on the warehouse floor.
5. Consistent Accuracy—Even with New or Temporary Staff
Unlike traditional picking methods, Pick to Light does not depend on experience.
New operators can:
* Become productive within hours
* Achieve the same accuracy as experienced staff
* Perform reliably during peak seasons
This consistency is a major reason warehouses report 99.9%+ picking accuracy after implementation.
As customer expectations continue to rise, error-free fulfillment is no longer optional. Pick to Light systems provide a practical, scalable way to achieve near-perfect accuracy without increasing labor complexity.
By guiding every action visually and validating every pick in real time, Pick to Light turns accuracy into a standard—not a goal.
Looking to reduce picking errors in your warehouse? Share your workflow and SKU profile with us (sales@sertag.com), and we'll help you design a Pick to Light solution that delivers measurable accuracy improvements.
