In today’s highly competitive manufacturing industry, efficiency and accuracy are the backbone of success. One small error in part selection can lead to defective products, production delays, and customer dissatisfaction. Traditional manual picking methods often rely heavily on operator judgment, which makes them prone to mistakes and time-consuming searches. To address these challenges, manufacturers are increasingly adopting Pick-to-Light (PTL) systems—a smart, technology-driven solution that transforms material picking and assembly processes.
At Warehouse International Pvt Ltd, we specialize in designing and delivering advanced PTL solutions for diverse industries. Our systems are built to minimize errors, speed up operations, and ensure real-time inventory accuracy. Recently, we successfully executed a PTL system project at Setco Auto System Pvt Ltd, Baroda, helping them streamline their assembly line operations and achieve remarkable improvements in accuracy and productivity.
What is a Pick-to-Light (PTL) System?
A Pick-to-Light (PTL) system is an error-proofing solution that uses LED indicators and digital displays installed at storage or bin locations to guide operators during part picking and assembly. When an order is initiated, the system illuminates the correct bin and shows the required quantity. Operators simply pick the highlighted parts and confirm the selection by pressing a button.
This simple yet powerful visual method reduces search time, eliminates confusion, and ensures the right part is picked every time. The PTL system can be seamlessly integrated with ERP/MES systems, enabling real-time tracking, data exchange, and inventory management.
Key Features of Pick-to-Light Systems
LED-Guided Selection – Bright indicator lights guide operators to the exact part location.
Digital Displays – Quantity information is displayed at each pick point for accuracy.
Error-Proofing Buttons – Operators confirm every pick, eliminating mistakes.
ERP/MES Integration – Enables seamless data flow and real-time order status updates.
Scalable & Flexible Design – Adaptable layouts for different assembly lines and production volumes.
User-Friendly Operation – Quick training and intuitive workflows for operators.
High Durability – Built for continuous industrial use with minimal downtime.
Benefits of Implementing a PTL System
Faster Picking Speed PTL systems enable up to 50% faster picking operations compared to traditional methods.
Reduced Errors Visual guidance minimizes mistakes, ensuring the right parts are picked every time.
Improved Productivity Operators spend less time searching and more time assembling.
Better Inventory Control Real-time updates provide accurate inventory data and traceability.
Easy Scalability Modular designs allow seamless expansion as production grows.
Enhanced Customer Satisfaction Error-free assembly leads to higher product reliability and fewer rejections.
Applications of Pick-to-Light Systems
Pick-to-Light systems are highly versatile and can be applied in multiple industries:
Automotive Assembly Lines – Ensures correct parts selection in complex assemblies.
Electronics Manufacturing – Reduces errors in PCB assembly and component picking.
Aerospace & Defense – Guarantees precision in high-value component assembly.
Consumer Goods – Speeds up order fulfillment and packaging processes.
Warehousing & Logistics – Optimizes picking accuracy for e-commerce and distribution centers.
Project Showcase – Setco Auto System Pvt Ltd, Baroda
One of our recent successful implementations was at Setco Auto System Pvt Ltd, Baroda, a leading player in the automotive components sector. Their assembly operations required a smarter picking solution to reduce human errors and enhance efficiency.
Before the Project
Manual part picking resulted in frequent errors.
Operators spent considerable time searching for the correct parts.
Delays in assembly due to inefficient picking processes.
Inventory mismatches created traceability issues.
Our Implementation
Warehouse International Pvt Ltd designed and deployed a customized Pick-to-Light system for Setco Auto System’s assembly line. The solution included:
LED indicators and digital displays at all critical part locations.
Error-proofing confirmation buttons to validate each pick.
Integration with ERP/MES for real-time order tracking.
Operator training sessions for smooth adoption of the system.
Real-time data synchronization improved inventory control.
Operator productivity improved due to faster and easier workflows.
Enhanced product quality and customer satisfaction.
This project highlights how Warehouse International Pvt Ltd empowers manufacturers with innovative, error-proof picking solutions tailored to their needs.
Why Choose Warehouse International Pvt Ltd for PTL Solutions?
Proven Expertise – Years of experience in designing and implementing industrial automation solutions.
Customization – PTL systems tailored to specific industry and assembly line needs.
Integration Capabilities – Seamless connection with ERP, MES, and other control systems.
Scalability – Modular solutions that grow with your production demands.
Successful Projects – Trusted partner for companies like Setco Auto System Pvt Ltd.
End-to-End Support – From consultation and installation to training and after-sales service.
By choosing Warehouse International Pvt Ltd, you ensure your operations are equipped with a future-ready, error-proof picking solution.
Industries We Serve
Automotive & Auto Components
Electronics & Semiconductor Manufacturing
Aerospace & Defense
Consumer Goods & Packaging
Warehousing & Logistics
Research & Development Labs
FAQs on Pick-to-Light Systems
Q1: What is a Pick-to-Light system? It is a visual guidance system using LED indicators and displays to guide operators to the correct parts during picking or assembly.
Q2: How does PTL reduce errors? By lighting the correct bin and showing the quantity, PTL eliminates confusion, while confirmation buttons validate the pick.
Q3: Can PTL be integrated with ERP/MES? Yes, PTL systems seamlessly connect with ERP and MES systems for real-time data exchange and order tracking.
Q4: Is the system scalable? Yes, PTL systems are modular and can expand to support increasing production needs.
Q5: How much productivity improvement can PTL bring? On average, PTL systems provide up to 50% faster picking and drastically reduce errors compared to manual picking.
Conclusion – Smarter Picking for Smarter Manufacturing
In today’s fast-moving manufacturing environment, accuracy, speed, and efficiency are critical. A Pick-to-Light system is no longer a luxury but a necessity for industries that want to minimize errors, improve productivity, and maintain reliable inventory control.
At Warehouse International Pvt Ltd, we are proud to be one of the leading PTL system providers in India, delivering cutting-edge solutions that align with Industry 4.0 requirements. Our successful implementation at Setco Auto System Pvt Ltd, Baroda demonstrates our expertise in transforming assembly line operations with innovative technology.
