Hello and welcome to a video introduction to Lightning Pick - the premier light-directed
order fulfillment package. This video illustrates the application of Lightning
Pick's core pick-to-light product to enhance the profitability of one of
the most popular and traditional order fulfillment approaches - zone picking.
This team-oriented methodology, also known as pick and pass fulfillment,
is effective in operations that have a high order volume and require fast order completion.
This video depicts several users, including a single operator, working in a single zone at
this distribution center. An order is associated with a barcode label which is then applied to a
reusable tote. Products for the order are picked into this tote. Totes are brought to the pick area
by conveyor. The operator scans the barcode label using a cordless scanner integrated by
Lightning Pick technologies. This launches the order sequence and Lightning Pick. The
order number assigned to the tote is displayed on the bay display for the zone. Light modules
illuminate at the required product locations and display the number of items to be picked. When the
pick locations are illuminated for an order, the operator can see all the associated picks
ahead of him and immediately knows which product location to go to next. The operator picks the
number of apparel items required, checks the sizes on each product label, and adds them to the tote.
After the picks are made, the operator hits the confirm button. The pick information is
automatically relayed to the host system in real-time.
Once the picks for the zone are complete, the operator closes
the tote and sends it along the takeaway conveyer. The operator then repeats this
process for the next order by scanning the barcode label on the next awaiting tote.
The Lightning Pick software also allows you to access real-time updates,
statistics and reporting, track productivity,
quickly add products and locations, and change staffing and work zones for maximum efficiency.
This retail distribution center illustrates high volume pick and pass multiple-zone operation. They
utilize Lightning Pick in their flow rack pick area for Walmart order fulfillment. Much like the
previous distribution center, this distribution center's host WMS, or order management system,
associates an order with a barcode label. However, instead of applying these labels to
reusable totes, this distribution center applies them directly to the outbound shipping container.
Products for the order are then picked into these boxes. This high-volume operation requires several
operators to work in one area where each operator is responsible for picking products
from their assigned zone. The first operator scans the barcode label, launching the order
in their assigned zone. While Lightning Pick can launch orders from the host system automatically,
many traditional team-oriented pick-to-light installations launch orders using cordless
scanners for simplicity and flexibility. This also enables Lightning Pick to track an individual's
productivity since operators must scan into their work zone. After the first operator scans a box,
the pick-to-light sequence begins. The operator begins picking items and adding them to the box.
Once the picks are completed for the zone, the operator sends the box down the roller
conveyor to the operator in the next zone who repeats this process: scan, pick, and pass.
After the second operator completes the picks in her zone,
the box is passed to the operator in the third zone.
Boxes that have no active picks in a zone can be passed on to the next zone,
or if the order is complete, the box can be put onto the takeaway conveyer without passing
through the remaining zones. Breaking the pick area down into zones significantly reduces the
walk time between product locations, allowing each operator to engage in more picking and
less travel. The Lightning Pick software can be used to change the number and size
of zones in an area to maximize productivity and account for available personnel. Lightning
Pick Technologies' physical installation was a snap. The project overall was a very positive
experience. My biggest concern was the integration between our Manhattan WMS and the Pick-to-Light
software. Working with Lightning Pick was the smoothest integration we have ever had. Lightning
Pick improved our accuracy from .32% to .0013% which has given us an $81,000 savings per year.
Lightning Pick has also eliminated many of the staffing and training headaches
common to distribution centers. Turnover is no longer an issue,
and training new staff only takes three days as opposed to the month it took before we
adopted Lightning Pick. We used to average 6,000 packages a day. After installing Lightning Pick,
we averaged 9,000 packages a day with half the staff. We more than doubled
productivity. We are saving somewhere in the neighborhood of $1.5 million dollars in labor.
As a supplier Lightning Pick Technologies has offered complete commitment to our Lightning
Pick installation by offering flexibility to our ever-changing order fulfillment needs.
Thank you for your interest in Lightning Pick Technologies and the Lightning Pick
light-directed order fulfillment package. The Lightning Pick suite of solutions also includes
Windows-based applications for container routing, RF picking modules, LP Communicate, LP Data
Journal and many others that add performance to your overall fulfillment operations. For
more information, please visit our website at lightningpick.com or call 262-250-2100 today.