Smarter Inventory Control with Pick-to-Light & Put-to-Light

Boost warehouse accuracy and speed with The Inventory Master’s cutting-edge light-directed automation systems.

Smarter Inventory Control with Pick-to-Light & Put-to-Light

We specialize in helping businesses optimize their warehouse and fulfillment operations with advanced Pick-to-Light and Put-to-Light systems. These light-directed solutions use visual indicators to guide workers in accurately picking or placing items, minimizing errors and maximizing efficiency. As a Detroit, MI-based leader in inventory control technology, we provide innovative, reliable, and scalable automation tools tailored for various industries.

Our collaboration with tech giants like GAO Tek and GAO RFID enables us to deliver top-tier solutions backed by cutting-edge research, continuous development, and robust quality assurance. Whether you run a distribution center or a retail backroom, our Pick-to-Light and Put-to-Light systems transform operations by reducing training time, improving order accuracy, and increasing throughput.

Warehouse workers use illuminated pick-to-light bins for order fulfillment accuracy.

Core Components of the Pick-to-Light and
Put-to-Light Systems

Hardware

  • LED light indicators (mounted on racks or shelving units): Zigbee End Devices are ideal for enabling smart LED light indicators that guide workers during pick-and-put operations with reliable low-power communication. 
  • Touch or sensor-based confirmation buttons: Z-Wave End Devices support touch/sensor interfaces that ensure accurate operator input in light-directed inventory workflows. 
  • Barcode/RFID scanners for validation: UHF RFID Readers, Tags & Accessories deliver fast item validation in high-throughput pick-to-light and put-to-light systems. 
  • Industrial-grade control panels: Device Edge hardware from our Edge Computing category empowers real-time control and processing at the warehouse floor level. 
  • IoT-enabled gateways for seamless connectivity: Wi-Fi HaLow Gateways/Routers provide long-range, low-power wireless connectivity ideal for IoT-enabled pick/put systems in large facilities. 

Software

  • Centralized control platform
  • Real-time inventory management interface
  • Order tracking and analytics dashboard
  • Custom rule-based logic for task execution
  • User access management and role-based permissions

Cloud Services

  • Secure, scalable cloud infrastructure
  • Remote monitoring and reporting
  • Integration-ready APIs
  • Encrypted data backups and multi-tenant architecture
  • 24/7 access to system diagnostics and analytics

Key Features and Functionalities

  • Visual item guidance with LED indicators
  • Real-time task updates and alerts
  • Hands-free workflow support with minimal training required
  • Error-proof confirmations using buttons or sensors
  • Batch picking and sorting capabilities
  • Adaptive zoning for team collaboration
  • Performance tracking and KPI monitoring

Benefits

  • Improves picking/placing accuracy by over 99%
  • Reduces labor costs and training time
  • Accelerates order fulfillment and reduces cycle times
  • Increases employee productivity
  • Enhances inventory visibility and traceability
  • Minimizes returns due to mispicks or misplaced items
  • Scales easily with growing operational needs

Integrations and Compatibility

  • Compatible with popular WMS, ERP, and MES platforms
  • Seamless integration with GAO Tek and GAO RFID technologies
  • Flexible API-based connectivity with custom business systems
  • Plug-and-play support for IoT edge devices, scanners, and mobile terminals

Applications

  • Order fulfillment in e-commerce warehouses
  • Retail replenishment and returns management
  • Manufacturing kitting and component staging
  • Cold storage and pharmaceutical handling
  • Cross-docking and shipment verification

Industries Served

  • Retail and E-commerce
  • Third-party Logistics (3PL)
  • Automotive and Manufacturing
  • Pharmaceuticals and Healthcare
  • Food & Beverage Distribution
  • Electronics and High-Tech

Case Studies

A major fashion retailer in Texas partnered with The Inventory Master to implement Pick-to-Light systems across their 150,000 sq. ft. fulfillment center. The result was a 40% reduction in order picking errors, along with a 25% improvement in throughput. The integration with their WMS allowed real-time updates and scalable operations during peak seasons.

A Detroit-based auto parts supplier deployed our Put-to-Light solution in their parts sorting facility. This enhanced kitting accuracy, minimized training time for new hires, and significantly reduced downtime due to misplacements. Within six months, ROI was achieved, and operational efficiency improved by over 30%.

An Ontario-based electronics distributor collaborated with us to streamline their multi-channel fulfillment using Pick-to-Light systems. Leveraging our integration with GAO RFID tools, they achieved real-time tracking, decreased item loss, and accelerated batch processing across multiple zones.

  • ANSI MH10.8.2 (Barcode labeling)
  • ISO 9001:2015 (Quality Management Systems)
  • OSHA 1910 Subpart N (Materials handling and storage)
  • CSA Z1000 (Occupational health and safety)
  • UL 508 (Industrial Control Equipment)
  • FCC Part 15 (Radio frequency devices)

Ready to Streamline Your Warehouse Operations?

Contact The Inventory Master today for customized solutions, technical support, or consultation on our Pick-to-Light and Put-to-Light systems. Our experts are here to help you unlock the full potential of light-directed automation.Get in touch now  and discover how we can support your business success.

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