Pick-To-Light System for Warehouse Order Fulfillment

Product: AI-Integrated Pick-To-Light System
Role: Senior Product Owner / Warehouse Automation Architect
Goal: Streamline order fulfillment, eliminate picking errors, and optimize warehouse efficiency.
Result: Dramatically reduced time spent locating items, eliminated incorrect picks, and accelerated overall order processing.

🚀 Core Responsibilities & Product Ownership

Product Vision & System Design

  • Designed and implemented an intelligent Pick-To-Light system that guides warehouse staff directly to the correct items using visual indicators.

  • Defined epics, user stories, and acceptance criteria to align hardware, AI, and WMS integration.

  • Focused on maximizing efficiency, minimizing errors, and improving throughput in high-volume warehouse operations.

🔥 Key Features & Functions Developed

 

1. Visual Picking Guidance
  • Lights installed above or next to product locations illuminate in real time for each order.

  • Workers are guided precisely to the correct SKU, quantity, and location, eliminating manual searching.

2. Error Prevention & Accuracy
  • Lights paired with sensors or scanners to confirm correct item selection.

  • Prevents mis-picks, wrong quantities, and shipping errors, reducing returns and rework.

3. Real-Time Order Coordination
  • Integrated with warehouse management software (WMS) to dynamically update pick lists.

  • Supports simultaneous pickers and batch orders without conflicts.

  • Ensures accurate, real-time processing of multiple orders.

4. Navigation & Time Savings
  • Eliminates the need to manually read picking lists or walk inefficient routes.

  • Lights direct workers instantly to the correct aisle and shelf, significantly reducing walking and search time.

  • Cuts order fulfillment cycle time substantially per order.

5. Scalable & Flexible System
  • Supports multiple zones and aisles, adaptable to changing inventory layouts.

  • Can be scaled for high-volume warehouses with minimal reconfiguration.

📊 Impact
  • Saved hours per shift by eliminating manual searching and inefficient walking.

  • Eliminated mis-picks, reducing operational errors, returns, and rework.

  • Increased order fulfillment speed and accuracy, improving overall warehouse throughput.

  • Enabled efficient batch picking and order consolidation, boosting productivity.

  • Reduced training time for new staff, as visual cues guide them intuitively.

💡 Key Skills Highlighted

  • Pick-To-Light system design & implementation

  • Warehouse automation & process optimization

  • Real-time WMS integration

  • Operational efficiency & throughput improvement

  • Error reduction & quality assurance

  • AI-assisted guidance and dynamic indicators

  • Scalable warehouse solutions
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